Market size and growth - NXP Semiconductors...20000 25000 30000 2 010 2 012 2 014 2 015 2 016 Kunits forecast Micro Hybrid Mild-hybrids Full, Plug-in HEV EV 0 5 000 10 000 15 000 20

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• Market size and growth

• Many years of experience

• Inverter review

• EV /HEV tear downs

• Importance of packaging

• Basic motor control

• Partnering for quick market access

• Overview of the Fuji / Freescale High Power IGBTs

• EV / HEV impact on semiconductor supply

• The Systems Solution

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• The electrification of the automobile is well under way and accelerating every day.

• EV / HEV is a fast growing part of automotive electronics.

• This presentation will provide a mid to high level view of the various types of EV / HEV architectures and the High Power IGBTs that enable the traction motor drive electronics.

• We‟ll discuss the new Fuji alliance which enables Freescale to provide the total EV systems solution now including Automotive High Power IGBTs.

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• 3

Chevy Volt

Think City

Nissan Leaf

Toyota Prius Tesla Motors

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0

5000

10000

15000

20000

25000

30000

2 010 2 012 2 014 2 015 2 016

Kunits forecast

Micro Hybrid Mild-hybrids Full, Plug-in HEV EV

0

5 000

10 000

15 000

20 000

2 010 2 012 2 014 2 015 2 016

Kunits forecast

Micro Hybrid Mild, Full, Plug-in HEV EV

Source: S.A.2009 Source: Valeo 2009

Source: S.A.2009 + FSL

(1) Analysts have increased the HEV semiconductor TAM by 10% within one year

Technologies available within FSL

Technologies available within FSL

Technologies available through Fuji

Alliance

Application Product 2009 2014 2018 Micro Hybrid, Low Voltage Battery Mgt MCU $1 $3 $7

Analog $16 $43 $75

Micro Hybrid Start/Stop MCU $7 $36 $64

Analog+ low votage power $33 $134 $268

Sub Total Micro Hybrid $57 $216 $414

Application Product 2009 2014 2018 HEV ( all type, all applications) MCU $25 $104 $152

Analog $31 $125 $188

Power High Voltage $290 $1,256 $1,840

Sub Total HEV $346 $1,485 $2,180

Grand Total Micro Hybrid + HEV $403 $1,701 $2,594 (1)

Semiconductor SAM (million US$)

Toyota Global Sales of Hybrids Top 3M Vehicles (3-/11)

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1.21 Giga Watts!

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• Collocated EV team in Phoenix with the necessary skills to do:

− Competitive analysis / existing product evaluation

− Learning – gaining knowledge (general / specific)

− Providing answers to specific questions (test understanding)

− IP & patents

− Product ideas that may / will cross MBGs (Silicon System Solutions)

− Define new potential products. Provide requirements / prototypes

− Help with evaluation of potential partners / acquisitions

− Integrate products / leverage ideas from across the Corporation

− Provide an environment for rapid prototyping

− Testing / making business case on new concepts

− Validating new ideas / inventions

− Moves Fast

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Micro Hybrid Mild Hybrid Full Hybrid Plugin Hybrid Battery EV

Features

Start/Stop Start/Stop Regenerative

Braking

Start/Stop Regenerative

Braking Power Assist


Braking Power Assist Electric Drive



Extended Electric Drive

Plugin Grid



Extended Electric Drive

Plugin Smart Grid

Connectivity

ICE Conventional Conventional Downsized Downsized Downsized None

Electric Power range (kW)

2 - 4 4 - 10 10- 20 25 - 60 30 - 80 30 - 150

OEM example BMW, PSA,

Huyndai, Mazda Ford EcoBoost Honda, Buick

LaCrosse, Toyota, Ford, GM Volt, Toyota

Prius, Leaf, Tesla, i-

MieV

Tier1s involved

Valeo, Bosch, Denso, Delphi;

Hitachi

Valeo, Bosch, Delphi, Conti, Hitachi,

Valeo

Denso, Bosch, Conti, Delph,

Toyota, Hitachii

Bosch, Delta Q, Hitachi, Valeo,

Delphi

Bosch, Delta Q, Hitachi, Valeo,

Delphi

Power Device Technology

Low Power (40V)

Low Power (65V)

Low/High Power

(60 - 250 V)

High Power ( > 400V AC)



Analog Mixed Signal

Power supply Networking Hbridge Pre-

driver

Power supply Networking

Hbridge Driver

Power supply Networking Gate driver




MCU range 8 / 16 bit 8 / 16 bit 16 / 32 bit 32-bit 32-bit 32-bit

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• Ford Hybrid

−2.5L ICE

−CVT Transmission

−Dual Motor/Generator

PWR

+20V

Temp

I limit

PWM

-8V

Driver

Controller

De-saturation & Active clamp

Gate feedback

Current sense

Micro

Controller

Vcc

Position

Over Temp, Over / Under Voltage, Over Current

1 of 6

Switches

Computation Galvanic Isolation IGBT Gate Control & Fault Detection IGBT Batt Mgnt

400+ Volts

LEM

BM

S

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TD350

DC DC

ISO

Signal

Cond.

Fault

Latch

MPC5674F

I

&

O

T

U

&

I

S

M

A

MPC5604P

C

A

N

C

A

N

Power

Supply

Power

Supply

PMSM

TD350

DC DC

ISO

TD350

DC DC

ISO

TD350

DC DC

ISO

TD350

DC DC

ISO

TD350

DC DC

ISO

Udc & I

Temp

H

A

L

L

H

A

L

L

H

A

L

L

VDC (300V) VBATT (12V) Isolation

barrier

RES

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65kW Prototype Inverter Being Developed for A Major Auto MFG

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• ICE and Electric work to together

•Regen brakes and CVS transmission

•Extended city range, reduced emissions vs. gas only

•Engine charges battery while driving

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• Impressive power from electric traction motor

•Regen brakes capture otherwise wasted energy

•Recharge at any 120V outlet

•3 to 4 Hr. charging using 240V charging station

•No tailpipe emissions

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• Very creative use of planetary gears

− Electric only traction motor

− ICE through generator to motor

− Generator used as motor paralleling traction motor

− ICE direct drive through the generator. Generator still powers the traction motor

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Heatsink

SubstratePower Dies Output Connection

DRIVER SECTION

CONTROL SECTION

DC/DC Dies

Coolantoutlet

Coolant inlet Charger Dies

POWER SECTION

Liquid Coolant

Inverter

Cooling

DC/DC+AC/DC

Current SensorPower dies driver

MCU

Supporting Components and Housekeeping Power Conversion

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• Max. output 20kW

• Max. torque 490Nm

• Max. velocity 150km/h (when built into 14" tires

• Mass Approx. 20 kg

• Reducer type Cycloid reducer

• Reduction ratio 1/11

• Motor type

• Axial gap type permanent magnet

• synchronization motor

• Max. motor speed 15000rpm

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DC Motor Commutation

• The stator of a Permanent Magnet DC Motor is

composed of two or more permanent magnet pole

pieces.

• The rotor is composed of windings which are

connected to a mechanical commutator. In this case

the rotor has three pole pairs.

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Brushless DC Motors Basic Structure

Requires mechanism to sense rotor

position to commutate field properly. This

is usually a hall effect

sensor array or an encoder i.e.. resolver.

Permanent magnet (usually ferrite,

samarium cobolt, or neodymium iron boron)

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• Six Step BLDC Motor Control (3ph)

− Voltage applied on two phases only

− It creates 6 flux vectors

− Phases are powered based on rotor position

− This process is called Commutation

Power Stage Phases voltage

= off

= on

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VBus

PWM1

PWM4 PWM2

PWM3

PWM5

PWM6

Three-phase PWM waveforms and harmonic spectrum. Source: Power Electronics, by Ned Mohan, Tore Undeland, and William Robbins, John Wiley & Sons, 1995

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B

C

A

PWM PWM1

PWM4 PWM2

PWM5

PWM6

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• Used to create the AC waveforms in the motor

but different than PWMs.

− PWMs treat each phase individually.

2 PWM channels per phase

− SVM treats the inverter as ONE unit!!

ALL 6 switches affected

− PWMs control the phase voltages.

-120° offsets between A, B and C

− SVM controls the Voltage Vector.

− Benefits:

Excellent Torque and speed control

Aligns well with digital control algorithms

− Disadvantages:

More micro HP needed

Peter Pinewski

B C A

1 = Top Switch is on

0 = Bottom Switch is on

The inverter can be driven to 8 states.

- 2 null vectors

- 6 voltage

vectors V4 = 100 V6 = 110

V2 = 010 V3 = 011 V1 = 001

V5 = 101

V0 = 000 V7 = 111

* Field Oriented Control (FOC) or Vector Control of a 3-phase AC

motor involves imitating the DC motors' operation. All controlled

variables are transformed to DC instead of AC via mathematical

transformation. The goal is to control torque and flux independently.

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• What Are We Seeking:

− Access to auto qualified IGBT, Diode components, modules

− Influence over IGBT, module roadmap

− Ability to get to market quickly

− Profitable cooperation model

− Security of supply

• Fuji IGBTs

• 600V / 400A Half H Bridge

• High speed switching

• Low inductance module structure

Semikron

Packaging

Modules

Danfoss

Packaging

Modules

Cooling

Potential Partners

MaxQ Cold plates

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Freescale Semiconductor and Fuji Electric partner to increase

efficiency of hybrid electric vehicles

Freescale enhances its powertrain portfolio with Fuji Electric IGBT technology to help improve automotive industry‟s „miles per watt‟

AUSTIN, Texas –April 11, 2011 – Freescale Semiconductor has entered into a strategic alliance with Fuji Electric Co., Ltd. to collaborate on insulated-gate bipolar transistor

(IGBT) technology and products for hybrid electric and electric vehicles (HEV and EV). Working with Fuji Electric, Freescale will add high-power IGBT products to its existing

portfolio of solutions for electronic powertrain applications, market those products to its automotive customers and define and produce new products based on customer

input.

IGBTs are currently the largest segment of the market for EV power systems. With the addition of IGBTs to its portfolio, Freescale will offer all of the major electronic

components of EV systems, including microcontrollers, analog gate drivers, battery monitoring ICs, power IGBTs and modeling / simulation tools, and software components /

tools for motor control development.

The IGBT is a high-voltage, high-current switch connected directly to the traction motor in a hybrid electric or electric vehicle. It takes direct current energy from the car‟s

battery and, through the inverter, converts the alternating current control signals into the high-current, high-voltage energy needed to commutate or turn the motor. The IGBT

is an ideal motor inverter switch for 35 KW to 85 KW EV motors due to its high efficiency and fast switching. The more efficient the IGBT, the less power is lost to wasted

heat, resulting in better mileage or “miles per watt” (MPW) of energy.

“Freescale chose Fuji Electric‟s IGBT technology based on its high-performance characteristics and capability,” said Tom Deitrich, senior vice president and general

manager of Freescale‟s RF, Analog and Sensor Group. “Coupled with Freescale‟s automotive portfolio and pedigree, this alliance accelerates our ability to provide

automotive customers with higher-efficiency inverter solutions.”

“We are pleased to work with Freescale on IGBT technology and draw on their automotive capability. This alliance will enable our IGBT technology to contribute to the

increased efficiency of electric vehicles,” said Kuniaki Yanagisawa, executive officer and general manager of Fuji Electric‟s Electronic Devices Business Headquarters.

Freescale is a leader in the automotive semiconductor industry with a successful legacy in powertrain electronics. With its microcontrollers designed into many EV systems

today, Freescale is well-positioned to supply customers with IGBTs and other devices that will be critical to the advancement of the electric vehicle.

About Fuji Electric

Fuji Electric is a leading company providing solutions for Energy and the Environment with its wide variety of products. Power semiconductors, one of its competitive product

categories, are essential in the reduction of energy consumption in electric vehicles, industrial machines and home electronic appliances. Further information is available at

Fuji Electric Group web site: http://www.fujielectric.com

About Freescale Semiconductor

Freescale Semiconductor is a global leader in the design and manufacture of embedded semiconductors for the automotive, consumer, industrial and networking markets.

The privately held company is based in Austin, Texas, and has design, research and development, manufacturing and sales operations around the world.

www.freescale.com.

http://www.fujielectric.com/

http://www.freescale.com/

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Customer Sampling June Under Development

Under Planning In Production

Voltage: 650V

Current: 400A

Voltage: 650V

Current: 600A

Voltage: 650V

Current: 900A

Voltage: 1200V

Current: 600A

Motor Output

Up to 146kW

Motor Output

Up to 180kW

Motor Output

Up to 65kW

Motor Output

Up to 97kW

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IGBT Diode

One 6” Fab Required per 1 Million EVs Cars!

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208 Diodes .42 X .24

Inch on a side

Die layout on a 6” Wafer

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• Single Motor / Inverter needs 18 IGBTs and 18 diodes

• 5.05 Cars / 6” IGBT Wafer -> 198, 019 Wafers / Million Cars

• 11.55 Cars / 6” Diode Wafer -> 86,580 Wafers / Million Cars

• 284,599 Total 6” Wafers / Million Cars

• 6” Fab outputs 750 Wafers / Day 273K /Yr.

• So What?

91 IGBTs .4 X.43

Inch on a side

Die layout on a 6” Wafer

One 6” Fab per 1 Million Cars!

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• Control Algorithms Leverage Chip Level Features

• Control algorithms to exploit Motor

specific MCU IP blocks, intelligent gate

driver control & local IGBT current

sensors; improve efficiency, tighter

control loops

• Comm protocol to interface between

gate, sensor, MCU

•MCU drivers capable to operate and

protect the module; auto quality required

• SW init tools to generate settings within

SOA (safe operating area)

• Models of the Module+Driver (Matlab,

Spice)

• Application examples

Control/MCU Board

Application SW

External HW

IGBT Module

IGBT Drivers

Add

On-Chip

Peripherals

Drivers

API

Algorithm

API

SW Tools

Drivers

Algorithm

Libraries

Control/MCU BoardControl/MCU Board

Application SWApplication SW

External HW

IGBT Module

IGBT Drivers

Add

On-Chip

Peripherals

Drivers

API

Algorithm

API

SW Tools

Drivers

Algorithm

Libraries

Nic

e t

o h

ave

Dif

fere

nti

ato

rs

Mu

st

have

Requires ability to

communicate bi-

directionally across

isolation barrier

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Session materials will be posted @

www.freescale.com/FTF Look for announcements in the FTF Group

on LinkedIn or follow Freescale on Twitter

• How many Giga Watts to get back to the future?

• Partnering allows Freescale quick access to the

Automotive EV / HEV market

• Fuji has many years of IGBT experience and

Freescale has many years of Automotive

experience

• The value add will come as we add IP i.e.

packaging, integration, PnP gate drive, etc.

• Freescale is investigating potential efficiencies for

the entire Electronic Traction Motor Inverter

system with the goal of achieving the industries

best MPW (Miles Per Watt)

http://www.freescale.com/FTF

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Documents

Market size and growth - NXP Semiconductors...20000 25000 30000 2 010 2 012 2 014 2 015 2 016 Kunits forecast Micro Hybrid Mild-hybrids Full, Plug-in HEV EV 0 5 000 10 000 15 000 20