Vehicle Electrification Application Focus
ST is making Driving Greener 2 Vehicle Electrification Electrification Technologies Proces What Electrification Means Product Use of a range of technologies to use electric power to replace some or all of the propulsion requirements of a vehicle
Data Points - Electrification 3 The Need for Greener Driving Transportation represents 110000000000000000000 JOULES of energy consumed per year for transport 23 % of the total CO 2 emissions from fuel combustion 28 % Of global final energy demand Source: iiea.org
Data Points - Electrification 4 The Need for Greener Driving Vehicle emissions represent 200,000 early deaths per year in the U.S. 8 % of total petrol consumption 10 % of the total CO 2 generated by humans
Data Points - Electrification 5 Electrification : The Greener Vehicle 750,000 Electric Vehicles sold WW in 2016 29 % of electric vehicle sales vs total sales in Norway 40-70 Million Estimated Total EV s in 2025
Global Electric Vehicle Production 6 8,000 Global Electric Vehicle Production Forecast K Units 7,000 6,000 5,000 4,000 3,000 2,000 1,000 0 Mild Hybrid Full Hybrid Plug-In Hybrid Battery Electric 2018 2020 2022 2024 Source: Strategy Analytics Oct17
Battery cost is the main difference between ICE and EVs 7 BEV and ICE pre-tax prices in U.S. for medium segment price, 2010-2030 (thousand 2016$ and %) Source: Bloomberg New Energy Finance Jun17
$ per kwh Million vehicles EV market trends 8 Battery costs fall EVs demand rise By 2025 EVs will cost same as internal combustion engine vehicles Cost for Li-ion batteries * EV projected (cumulative) sales * 500 1000 400 Annual sales Cumulative sales 800 600 300 400 200 200 100 2010 2015 2020 2025 2030 2015 2020 2025 2030 2035 Source: Bloomberg New Energy Finance
Electric Vehicle Classification 9 Electric Vehicles can be classified by the degree to which electricity is used to power the vehicle There are many degrees and classifications possible Typical main ones are Hybrid Electric Vehicles (HEVs) Plug-in Hybrid Electric Vehicles (PHEVs) Battery Electric Vehicles (BEVs) Others include Micro-Hybrids Mild-Hybids
Electric Vehicle Classification* 10 Micro-Hybrid Electric Vehicles Basic Start/Stop functionality, switches off the engine and restarts it using the battery Mild-Hybrid Electric Vehicles Mild Hybrids use a motor starter/generator unit (MGU), connected to a battery. The MGU charges the battery and assists in vehicle acceleration after Start/Stop. Hybrid Electric Vehicles (HEVs) HEVs are powered by an internal combustion engine (ICE) and an electric motor. Batteries are charged via regenerative braking and optionally by a generator connected to the ICE. Plug-in Hybrid Electric Vehicles (PHEVs) PHEVs are HEVs with an on-board charger (OBC) that allows the batteries to be charged from an electric power source. ICE used only as a backup. Battery Electric Vehicles (BEVs) 100% use of electric power, no ICE. Batteries charged from electric power source and regenerative braking. *There are many varieties and topologies of all of the classifications listed. These are the most common definitions
Electrification: the 3 Degrees Electric Vehicles Can Be Classified by the Degree to which Electricity is Used to Power the Vehicle 11 Hybrid Electric Vehicles (HEVs) HEVs are powered by an internal combustion engine (ICE) and electric power. Batteries are charged via regenerative braking and optionally by a generator connected to the ICE. Plug-in Hybrid Electric Vehicles (PHEVs) PHEVs are HEVs with an on-board charger (OBC) that allows the batteries to be charged from an electric power source. Battery Electric Vehicles (BEVs) 100% use of electric power. Batteries charged from electric power source and regenerative braking. 100 % + Extended Range, Lower emissions than ICE only + Greater Electric range than HEV, ICE used as backup only + Zero Emissions, Lower maintenance - Use of fossil fuels, complexity of the solution Examples: Toyota Prius, Ford Fusion Hybrid - Use of fossil fuels, complexity of the solution Examples: Chevrolet Volt, Mitsubishi Outlander P-HEV - Range/Cost of Battery Examples: Tesla (all models), Nissan Leaf
Electrification: the 3 Degrees 12 Electric Vehicles can be classified by the degree to which electricity is used to power the vehicle HEV PHEV BEV 100 % Hybrid Electric Vehicle Plug-in Hybrid Electric Vehicle (Battery) Electric Vehicle
Electrification Mild to Full BEV 13 Electric Vehicles can be classified by the degree to which electricity is used to power the vehicle MHEV HEV PHEV BEV 100 % Mild Hybrid Electric Vehicle Hybrid Electric Vehicle Plug-in Hybrid Electric Vehicle (Battery) Electric Vehicle
Electric Vehicle Classification 14 Micro-Hybrid LV 12V + Extended Range, Lower emissions, Simple - Use of fossil fuels Mild-Hybrid LV 48V + Extended Range, Lower emissions, Simple - Use of fossil fuels Full-Hybrid HV + Extended Range, Lower emissions - Use of fossil fuels, solution complexity Plug-in Hybrid HV + Greater Electric range than Full-Hybrid, ICE as backup only, lower emissions - Use of fossil fuels, solution complexity Full BEV HV + Zero Emissions, Lower maintenance - Range/Battery Cost LV - Low Voltage <60V DC HV - High voltage >60V DC
Some* examples of the different electric vehicles in the market On the Road 15 Micro-Hybrid LV 12V BMW 1/3 series, Fiat 500, Peugeot Citroen C3, Mercedes-Benz A-class Mild-Hybrid LV 48V 2017 Buick LaCrosse eassist, 2017 Renault Scenic, 2018 Chevrolet Malibu Hybrid Full-Hybrid HV 2017 Ford Fusion Hybrid / Energi, 2017 Toyota Highlander Hybrid, 2017 Porsche Panamera Hybrid Plug-in Hybrid HV 2017 Audi A3 Sportback e-tron, BMW 330e iperformance, 2017 Kia Optima Plug-In Hybrid, 2017 Volvo XC90 T8 Full BEV HV Tesla All models, Chevrolet Bolt, Renault Zoe, Hyundai Ionic Electric, BMW i3 LV - Low Voltage <60V DC HV - High voltage >60V DC *Other examples from other manufacturers are available
ICE and EV Comparisons 16 ICE HEV PHEV BEV Cost per mile * $11cents/mile $7cents/mile $8cents/mile GAS $4cents/mile ELEC $4cents/mile Exhaust emission * 100gr/mile 0 gr/mile 250gr/mile 400gr/mile Range 300-500miles 400-500miles 200-300miles 200-400miles Refuel time 5-10mins 5-10mins 10-600mins 40-1400mins Source: US Dept. of Energy
ICE and EV Comparisons 17 ICE HEV PHEV BEV Cost per km * $7cents/km $4cents/km $5cents/km Petrol $2.5cents/km ELEC $2.5cents/km Exhaust emission * 60gr/km 0 gr/km 150gr/km 250gr/km Range 500-800km 600-800km 300-500km 300-500km Refuel time 5-10mins 5-10mins 10-600mins 40-1400mins Source: US Dept. of Energy
The Transition to Electric Will Take Time ICE Opportunities for Greener Driving 18 ST provides silicon solutions for a broad range of Engine Management Systems, from motorbikes to multi-cylinder Gasoline Direct Injection and common-rail diesel engines as well as transmission control and actuation Opportunities for Automotive MCUs Standard Low-side, High-side and Bridge Smart Power Devices for driving solenoids, DC motors and stepper motors Dedicated ICs for actuator driving, charging and power management Power MOSFETs and IGBTs
Electric Vehicle User Benefits 19 Greener Less pollution: EV s reduce harmful air pollution from exhaust emissions. When running on electric power there are zero exhaust emissions. EV s are quieter and reduce noise pollution Renewable energy: If renewable energy is accessible to recharge the EV, greenhouse gas emissions are reduced even further Eco-friendly materials: There is a trend towards more ecofriendly production and materials especially for EVs. The Ford Focus Electric is partly made from recycled materials Safer Many EV features can improve safety. The risk of fire is reduced to non-inflammable fuel. EVs often have a lower center of gravity that makes them less likely to roll over
Electric Vehicle User Benefits 20 Cheaper to run and maintain Cost of Electricity is typically one third as much per kilometer as buying petrol for the same vehicle State and local subsidies may reduce the cost of EV purchase and usage A battery electric vehicle (BEV) has fewer moving parts than a conventional petrol/diesel car and relatively little servicing Plug-in Hybrid Electric Vehicles (PHEVs) have petrol engines that need regular servicing so cost more to maintain. The shared electric power reduces petrol engine maintenance costs. Battery technology is improving. Most car manufacturers warrant EV batteries for around 8 years. (Source)
How Does it Work? Key Elements in Electric Vehicles 21 DC-DC HV Converts DC from the high voltage batteries (400V-700V) to a DC voltage required by the traction inverter Traction Inverter Converts DC Voltage into 3-phase AC at up to 200kW for the electric motor Battery management Systems (BMS) Manages the batteries for longevity and performance On-Board Charger (OBC) Converts AC from the Grid 95-265 V ac and converts to a DC voltage required for battery charging 400-800 V DC-DC 12 V Converts HV DC from the HV batteries to 12 V for use in legacy vehicle subsystems DC-DC 48 V Converts HV DC from the HV batteries to 48 V for use in vehicle subsystems
How Does it Work? Key Elements in Electric Vehicles 22 95-265 V 400-800 V 400-800 V 400-800 V AC DC DC DC AC OBC DC-DC HV 48 V Traction Inverter 48 V DC DC DC-DC HV/48 V 48 V Systems 12 V DC 12 V DC DC-DC HV/12 V 12 V Systems
Getting Started - Mild Hybrids 23 Mild hybrids are a low cost entry point for manufacturers and can reduce CO 2 emissions by up to 20% Mild Hybrids (typically) require a motor starter/generator unit (MGU), a DC-DC converter and a 48V lithium-ion battery, they provide a low-cost hybrid option Motor starter/generator unit (MGU) Is connected to the driveshaft and to the 48V battery Boosts the ICE during a start/stop event to improve acceleration Charges the 48V battery when the vehicle is running on ICE power and slowing down using regenerative braking 48V battery also provides power to the high-current elements (fans, pumps, AC etc.) and via a DC/DC converter provides power to a small 12V battery for the 12V legacy system MHEV Mild Hybrid Electric Vehicle Mild Hybrid examples include the 2017 Renault Scenic, 2017 Buick LaCrosse eassist, and 2017 Chevrolet Malibu Hybrid
Why 48V? 24 48V Networks are being used across all EV Classifications 48V electrical systems have advantages over current 12V systems, providing 4 times the power during recuperation The improved power is ideal when powering fans, pumps, electric power steering racks, and compressors Power 4X Higher voltages are more efficient, but automotive regulations demand costly shielded cabling (galvanic isolation) above 60V to protect occupants, so 48V keeps the cost down $$$48V
Mild Hybrids Affordable solutions for entry level electrification 25 Mild Hybrid Vehicles [Mu]* Mild Hybrid Vehicles [Mu] 15 12 9 6 3 0 2020 2021 2022 2023 2024 2025 48V Mild Hybrid Benefits Up to 15% CO 2 reduction due to lower power losses (start-stop) and energy recuperation -15 % CO 2 x3 ~13 In 2025 M Vehicles Battery management Systems (BMS) SiC MOSFETS IGBTs MHEV AC-DC 48V SiC MOSFETS IGBTs Affordable Access to Electrification with significant benefits Enabling quicker engine start, sharper acceleration, and higher performance in-car applications $$$48V DC-DC 48V/12V SiC MOSFETS IGBTs Additional Large range of protection, filter and companion ICs *Source: Average of estimations of IHS, Continental, IDTechEx, Bloomberg Mild Hybrid Electric Vehicle
Battery Electric Vehicles Disruptive market changing vehicles 26 Battery Electric Vehicles BEV ST Opportunities ST working closely with OEMs Engaged with key players in Car Electrification Supporting Car Makers with power modules on a worldwide basis ~85 % of the projects include SiC products 7x in Europe 4x in America 8x in China 3x in Japan 2x in Korea Traction Inverter SiC MOSFETS Galvanic Drivers Regulators 32-bit MCUs DC-DC HV SiC MOSFETS IGBTs + copacked diodes Galvanic Drivers 32-bit MCUs Battery Management System (BMS) 32-bit MCUs DC-DC HV/48V/LV Super Junction MOSFETs Trench Gate MOSFETs IGBTs BEV On-Board Charger SiC MOSFETS IGBTs SCRs, Diodes Galvanic Drivers 32-bit MCUs Fast Charger SiC MOSFETS IGBTs Additional Large range of protection, filter and companion ICs (Battery) Electric Vehicle
Power Challenges Power Solutions from ST 27 Car Electrification and Autonomous Driving enabled by Semiconductors Leading Edge Technologies and Solutions Vertical Intelligent Power Silicon Carbide Bipolar CMOS DMOS Improved figure of merit (lower on losses), higher dv/dt (lower switching losses) Working at higher PWM frequency & temperature High density to realize enhanced features, diagnostics, precision embedded intelligence High integration (SoC, SiP solutions) Shrink path and package miniaturization Advanced functional safety development flow (ISO26262) Advanced reliability and test methodologies
Smart Power Technology SiC Value Proposition 28 SiC Technological Benefits vs Conventional Silicon IGBT Higher Performance & Voltage Operation Extremely low power losses High efficiency at low current Intrinsic SiC body diode (4 quadrant operation) Higher Operating Frequency Lower switching losses Excellent diode switching performance Higher Operating Temperature Operating up to 200 C junction SiC Advantages for Automotive Electrification - mileage extension, smaller battery (or increased battery reliability), fast & efficient charging From ~2% (high load) to ~8% (low load) efficiency gain on average ~7x lower switching losses ~7x smaller chip size ~40% lower total loss (W) ~ 5..10 times higher switching frequency Lower System Cost ~5x reduced form factor & ~50% cooling system downsizing simpler sub-systems like smaller passives, no external freewheeling diode,
Smart Power Technology BCD Value Proposition 29 BCD Technological Benefits Higher Integration Integration of Bipolar, DMOS, CMOS & Memory Higher Energy Efficiency Best in class specific Rds-ON for power DMOS Wide voltage range components From 5V to 1200V, up to 6kV Galvanic Isolation Deep trench isolation Improved latch-up, substrate noise immunity and parasitic management Thick copper metallization Improved current capability Ni/Pd pad finishing Extended Temperature range up to 175 C BCD Advantages for Automotive R&D leadership and automotive experience multiple process technology generations 30years+ automotive experience Platform concept - multiple process options High voltage, SOI, advanced BCD, galvanic isolation embedded NVM option Process customization to support specific Automotive application requirements Automotive quality and reliability Built-in right from the beginning of the definition of a new technology node Cost optimization Leading lithography nodes Technology architecture enhancements
Smart Power Technology VIP Value Proposition 30 VIPower Technological Benefits High Integration in a single package Up to 8 actuator channels in QFN 6x6 Monolithic integration of Smart Trench FET technology with dense digital intelligence Higher Energy Efficiency From low to high Rdson High Current Actuation Up to 50A DC load for 12V, 24V and 48V Smart Interfacing Serial peripheral Interface / parallel interface Enhanced diagnostics SPI Drivers with autonomous synchronization of diagnostic during PWM operation Very low current sensing spread VIPower Advantages for Automotive >25 years VIPower in Automotive Comprehensive auto grade product families New high power loads & power distribution systems Support of new high power load functions Smart Junction Boxes replacing relays & fuses Suitable for ICE as well as HEV System simplification (HW and SW) SPI and ADC on board enable saving of I/O s Enhanced diagnostic result in higher robustness SW re-use and AUTOSAR compliant Miniaturization and reduced system cost Reduced number of external components Significant reduction of PCB space from generation to generation
F7 Low Voltage MOSFETS Value Proposition 31 F7 Technological Benefits RDS(on) continuous reduction FOM Reduction versus previous generations Miller Capacity Reduction Thanks to new sophisticated gate structure (double-electrode) Soft Capacity Ratio Crss / Ciss F7 shows excellent EMI performance Excellent Diode Performance F7 perfectly suitable for Synchronous Rectification Excellent avalanche Performance Technology is immune to dynamic dv/dt failure 175 C maximum junction temperature F7 is able to meet AG requirements F7 Advantages for Automotive Comprehensive auto grade product families Broad Packaging Portfolio PowerFLAT (DI), TOLL, LFPAK, D2PAK, DPAK Bare Die Business Known Good Die (KGD) Scalable Product Portfolio Different Voltage Classes 30V,40V, 60V, 80V & 100V Scalable R DSON starting in the sub mω range Excellent Switching performance Very stable switching performance to support high power 48V Power Grid Applications
ST Stands for life.augmented 32 Smart Driving is one of the 4 Smart Themes
Silicon Carbide Market and History
SiC MOSFET Target Applications 34 Power 350 kw Rail traction Smart Power Grid Wind mills HEV / BEV 100 kw 50 kw 30 kw 10 kw PHOTOVOLTAIC INDUSTRIAL DRIVES POWER SUPPLY / UPS ENERGY STORAGE CHARGING STATION 5 kw HOME APPLIANCE 1 kw NETCOM SERVER 600V 900V 1200V 1700V Rated Voltage
SiC Diode Target Applications 35 Power 350 kw CHARGING STATION 100 kw HEV / BEV ON-BOARD CHARGER 50 kw MOTOR DRIVES 30 kw 10 kw HIGH POWER SMPS POWER SUPPLY / UPS 5 kw 1 kw TELECOM NETCOM SERVER HOME APPLIANCE 600V 900V 1200V SOLAR INVERTERS Rated Voltage
20 Years of ST SiC History 36 April 1998 1st contract on SiC with CNR-IMETEM (Dr. V. Raineri) November 2003 First ST internal product request May 2004 Schottky Diode Demonstrator (ST line) March 2009 Power MOSFET 3" Demonstrator September 2014 1 st Gen MOSFET Start Production June 1996 Collaboration with Physics Dept. (Prof. G. Foti) February 2003 ETC Epitaxial reactor prototype installed in ST May 2002 Schottky Diode Demonstrator (CNR line) December 2005 Schottky Diode Mat 20 October 2007 1 st Gen Diode Start Production May 2012 2 nd Gen Diode Start Production September 2013 1.2kV Diode Start June 2014 Production 3 rd Gen 3 Diode Start Production June 2017 2 nd Gen MOSFET AG 6" Start Production 1996 1998 2000 2002 2004 2006 2008 2010 2012 2014 2016 June 2003 2" ST line June 2006 3" ST line June 2011 4" ST line June 2016 6" ST line Pioneers.....to mass production
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Higher Performance & Voltage Operation 38 Lower Rdson, Smaller Die Size for equivalent Breakdown Voltage SiC vs Si 1200V SiC vs. Si 1x 5x 8x 650V 100x SiC MOSFET Gen 2 Si IGBT Si SJ 1x 5x SiC MOSFET Gen 2 Si IGBT Si StripFET MOSFET
Higher Operating Frequency 39 1200V SiC MOSFET enables higher working frequency for smaller Passives and Cooling system Higher efficiency at High frequency Smaller passives Smaller heatsink Lower System cost and System size reduction Simpler topologies can be adopted Less design effort Inductor Size Reduction IGBT Heat-sink SiC Heat-sink
Normalized On Resistance Higher Operating Temperature 40 SiC operates at higher temperatures and has a lower RdsOn across temperature range ST Si MOSFET Competitor A SiC MOSFET Competitor B SiC MOSFET ST SiC MOSFET SCT30N120 Temperature ( o C) ST SiC MOSFET has the lowest Ron at high temperatures ST is the only supplier to guarantee max Tj as high as 200 C in plastic package
Efficiency (%) Faster Reverse Current Recovery 41 Turn-OFF COMPARISON 500W PFC, f=100 khz SiC VR= 400V ; IF= 8A ; Tj= 125 C di/dt= 200A/µs Si 0 SiC STTH806TTI STTH8R06 Temperature ( o C) 2A/Div, 20ns/Div STTA806
ST SiC Manufacturing 42 The process flow in SiC device fabrication is similar to that in Si technology, but several unique processes are also needed because of physical and chemical properties of SiC Special HT Epitaxy EPI defects classification and monitoring High temperature ion implantation Very HT dopants activation ST has been manufacturing Silicon Carbide since 2003 ST has extensive experience in SiC manufacturing 2003 2 line startup 2006 3 line startup 2011 4 line startup 2016 6 line startup
SiC MOSFET Technology Portfolio 43 Industrial and Automotive Grade 1200V and 650V ST has long consolidated experience in manufacturing Silicon and Silicon Carbide MOSFETs SiC 1 st Gen 1.2kV MOSFET in production since 2014 12 A (500mW), 20 A (169mW), 45 A (80mW), 65 A (52mW) 2 nd Gen 650V, 1.2 kv Automotive Grade in production from Q3 2017 650V: 50 A (50 mw), 110 A (20 mw) 1200V: 40A (40 mw), 90 A (25 mw) 1.7 KV in production from Q4 2017 6 A (1 W), 25 A (90 mw)
SiC Diode Technology Portfolio 44 ST has over 20 years experience in producing robust Schottky diodes SiC diodes are based on Schottky technology, on which ST is a leader 650V AG 6A, 10A, 12A, 20 2x10A, 2x20A 1200V AG Industrial and Automotive Grade 1200V and 650V 2A, 5A, 6A, 10A, 15A, 20A 2x5A, 2x10A, 2x15A, 2x20A
SiC Technology RoadMAP 45 MOSFET DIODE on losses*area (V/A*mm 2 ) trench JBS Schottky diode planar JBS (Junction Barrier Schottky) more Efficient Under Dev. : gen 3, gen 4 Under Dev. : gen 5, gen 6
From Planar to Trench 46 ST 4 th Generation SiC - TrenchFET TrenchFET key advantages: longer channel perimeter higher mobility on trench wall surface improved quality of channel surface self aligned gate source body Tatsuya Kimoto; Hiroki Yoshioka; T. Nakamura Wide Bandgap Power Devices and Applications (WiPDA), 2013 IEEE Workshop on