Power Electronics for xEVs

Jin Hwan Jung, Ph.DResearch & Development Division

June, 2015

Contents

I. xEVs Development Background

II. Hyundai Motor Group’s Activities in xEVs

III. Sonata HEV’s Power Electronic System

IV. Future Promising Technologies

V. Concluding Remarks

I. xEV Development Background

• Strengthened F/E regulation drive PT efficiency improvements

CO2 95g

60 mpg

I. xEV Development Background

• Alternative powertrain enlarges its market share gradually• HMG has several countermeasures to adapt the market change.

HEV 50%

I. xEV Development Background

II. HMG(Hyundai Motor Group)’s Activities in xEVs

Expanding Various Line-Up(Exporting to foreign markets)

Preparing for Mass-Production(Reduced costs by domestic core parts)

Securing Technology

1996First Concept

3PHASE 2010 -2PHASE 2006 - 2009 1PHASE - 2005

Price Competitiveness & Fuel Economy

2000 County Bus HEV(Support World Cup)

2004Click HEV(Fleet Program)

2006Pride/Verna HEV(Fleet Program)

2009 Forte/Avante LPI HEV (Mass Production)

2009BlueCity CNG HEV(Fleet Program)

2011 Sonata HEV (US & Korea Market)

2011Optima HEV(European Market)

2015 / 2016Plug-In Hybrid(Mass Production)

GHG / CO2 Regulation

Status - HEV II. HMG’s Activities in xEVs

Mass ProductionPreparing for Mass-Production(Fleet Program)

Securing Core Technology

3PHASE 2012 -2PHASE 2000 - 2011 1PHASE - 1999

1996Accent EV(CARB ZEV Certification)

2000Santa-Fe EV(Hawaii/Jeju Fleet)

2010 Blue-On (Small Scale Production)

2011Ray EV(Small Scale Production)

2014Soul EV(Mass Production)

2016Small Size Sedan(Mass Production)

1991Sonata EV

ZEV Regulation / etc.

Status - EV

Expand Charging Infra. / Improve Battery Performance

II. HMG’s Activities in xEVs

Small Scale ProductionPerformance ImprovementSecuring Stack Technology

3PHASE 2012 -2PHASE 2007 - 2011 1PHASE - 2006

Expand Hydrogen Infra. and Cost Reduction

2002Santa Fe FCEV

2006Tucson FCEV1st Gen.(80kW Stack)

2006FC BUS1st Gen.(160kW Stack)

2013Tucson FCEV

2007Tucson FCEV2nd Gen.(100kW Stack)

2008Borrego FCEV

2009FC BUS 2nd Gen.(180kW Stack)

201XNEXT FCEV

Status - FCEV

ZEV Regulation / etc.

II. HMG’s Activities in xEVs

III. Sonata HEV’s Power Electronic system

Unique Systemwith Full HybridFunction of HyundaiMotor Company

BetterFuel Economywith Parallel PowerOperation

PowerfulFun to Drivewith Dynamic GearShift Program

Sonata HEV III. Sonata HEV’s PE system

Traction motor

Interior Permanent Magnet for Torque increase

High slot-fill factor (Concentrated winding)

Torque(power) increase (max 25%)

Motor efficiency increaseEFFECT

FEATURES

▣ Interior permanent magnet(IPM) ▣ Concentrated winding

→ (same current) torque increase (max 25%): magnet torque(SPM) + reluctance torque(IPM)

[ SPM(Surface type) ]

Coil

Ec 0.5Ec

[ Concentrated ][ Distributed ]

→ Shorten end-coil (50%↑): Increase efficiency by lowering coil resistance

[ Separate core ]

ROTOR ASS’Y

Power transmitPM rotating fluxFlywheel func.(mass)

STATOR ASS’Y

E/G & T/M matchingMotor heat dissipationPower connection

III. Sonata HEV’s PE system

HSG High fill factor & cooling design optimization

Advanced NVH design in motor whine

Wide operating range(Low Speed & High Torque ~ High Speed & High Power)

Motor efficiency and continuous power range increaseEFFECT

FEATURES

▣ Advanced NVH design ▣ Distributed winding

→ minimize end-coil length→ maximize coil fill factor(40%↑): Increase efficiency

→ cooling design optimization: Increase continuous power range

α

βA

B

→ optimal E/M design: minimize torque ripple(4%↓)

→ robust Mechanical design: maximize dynamic stiffness: minimize vibration/noise level

III. Sonata HEV’s PE system

Hybrid System HPCU

HPCU system• HPCU (Hybrid Power Control Unit)

- Two inverters, dc-to-dc converter, hybrid control unit are integrated

A/T

Battery

E - Oil Pump

Inverter 1

RegenerativeBrake System

Motor

Inverter 2 HSG

converter

Integrated Control Board(Inverter1+Inverter2+LDC+HCU)

LDC(Low voltage DC to DC

Converter)Water cooling heat sink

III. Sonata HEV’s PE system

Battery System

Hybrid System Battery system

A/T

Battery

E - Oil Pump

Inverter 1

RegenerativeBrake System

Motor 1

Inverter 2 HSG

LDC

Battery Module

Power Relay Assy

BMS

Cooling Fan

III. Sonata HEV’s PE system

Battery System

• Battery System Package- Secure maximum cargo volume across the segments through battery location change

Old model NEW model

III. Sonata HEV’s PE system

EMI/EMS - Electromagnetic Coupling

Band ServiceFrequency

[MHz]

AM AM radio 0.531~1.602

FM FM radio 88.1~107.9

DMBDigital Multimedia

Broadcasting174~215

RFIDRadio Frequency

MultimediaBroadcasting

13.56, 433, 860~960

RKE Remote Keyless Entry 315, 433.92

CDMACode Division

Multiple Access824~894

GPS Global Position System 1574~1577

PCSPersonal

Communication System

1750~1870

WCDMA Wideband CDMA 1920~2170

WiBro Wireless Broadband 2300~2400

Bluetooth Bluetooth 2400~2483.5

SDMB Satellite DMB 2605~2655

Radar Radar 24~24.45[GHz]

Antenna(AM,FM,DMG,GPS,…)

Rear radar

side radar

Audio System Navigation

system

Front radar

Inverter/converter

Motor

Engine

HV battery

RKE

BMS

Radiated coupling

Conducted coupling

Electromagnetic Coupling path of HEV

III. Sonata HEV’s PE system

IV. Future Promising Technologies

SiC – Inverter / Converter

• SiC vs. Si : Breakdown Electric field(X10) & Higher Energy Gap (X3):

Futureworks

Cost reduction

: SiC is over 5-times higher than Si (Reduction in need for at least 2-times or less)

Package development for high operating temperature

: Target Temp. is 150℃250℃

System Optimization considering Efficiency & Cost/Size

Fuel Efficiency Increasing Down sizing & Low NVH Advanced Cooling Systems

SiIGBT

SiC FETMaxPower

SiC FET

Si IGBT

Static loss↓ Dynamic loss↓(Switching Frequency↑)

Loss↓ → Efficiency↑

① Passive Components(L, C) size↓

② Switching frequency↑ NVH ↓(Audible Frequency : ~16kHz)

Capacitor & Inductor ↓

SiPCU

SiCPCU

(1/2?)

Operating Temperature(65~150 ℃ →110~250 ℃)

Optimized Cooling System(Cost, Mass, Size ↓)

65 ℃110 ℃150 ℃250 ℃

Si PCU SiC PCU

Engine Coolant Temp

EnginePump

Pump

EnginePump

(1/2~1/3?)

Current

IV. Future Promising Technologies

WPT(Wireless Power Transfer) System

AC /DC

Resonant topology,

Filter capacitorBattery

Rectifier + Filter

VehicleInfra.

WiFi Comm. WiFi Comm.

TxCoil

Rx

Coil

Wireless PowerTransfer between

81kHz-90kHz

AC

Measurementsfeedback

Standard for CoilStandard Coil type for WPT is not fixed yet.Compatibility between Coil types (Circular or Solenoid or DD)

Tolerance for alignmentRobust charging performance for misalignment & ground clearanceAlignment Method is required using magnetic coupling, RFID, Camera

Wireless communicationHigh accessibility (DSRC or WiFi)

Object DetectionFOD : Foreign Object Detection / LOD : Live Object Detection

Futureworks

IV. Future Promising Technologies

V. Concluding Remarks

Concluding RemarksI. Automakers are developing xEVs to satisfy the regulations.

II. Power Electronics is the core technology for xEVs.

III. HMG has developed and applied competitive motors, inverters, converters, batteries to xEVs.

IV. Automotive area has required several characteristics : low cost, high efficiency, compact size, light weight, reliability

V. New technologies such as SiC, wireless power transfer, etc. should be well prepared and managed in advance.

VI. New technologies of Power Electronics can make the innovation in vehicles.

V. Concluding Remarks