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Circuit Protection on High Reliability Electric Vehicles (EVs) International Forum on Innovation and Development of Electric Vehicle Electronica Shanghai 14 March 2017
2 Confidential and Proprietary | Littelfuse, Inc. © 2017 2 Confidential and Proprietary | Littelfuse, Inc. © 2017
Agenda
Market for EV / HEV Vehicles EV / PHEV Architecture EV Sensing Line Protection vs. BMS and Battery
Pack Architecture Battery Management System and Protection
Devices Summary EV Charger System (On-Board and Off-Board
Charger) IGBT/MOSFET Protection Summary and Conclusion
3 Confidential and Proprietary | Littelfuse, Inc. © 2017 3 Confidential and Proprietary | Littelfuse, Inc. © 2017
The Market for EV / HEV Vehicles Growth Drivers and Types of EVs
Market for vehicles with any form of higher voltage (>12 or 24V) electric system is expected to show CAGR of ~15% to ~30% until 2020.
In addition to the growing number of BEV, PHEV and HEV cars, the new 48V Mild Hybrid or Eco Drive systems will significantly contribute to the growth.
Key driver is the demand for improved air quality by lower or zero emissions, requiring better efficiency of cars. Additional driver is the growing number of electric loads in vehicles, requiring higher voltages and more powerful electric
systems.
Source: Navigant Research 2013 Source: CONTINENTAL AG 2013
4 Confidential and Proprietary | Littelfuse, Inc. © 2017 4 Confidential and Proprietary | Littelfuse, Inc. © 2017
EV / PHEV Architecture Main Building Blocks
12V Lead Acid
Battery
48V Li Ion Battery
µC
CM
High V Li Ion Battery Pack
CM
CM
CM
CM
µC
µC
BMS / Charge Controller
DC DC Converter
On Board Charger
120V / 250V AC
DC
Electric Motor
Electric Coolant Pump
PTC Heater
Electric Vacuum
Pump
• Infotainment • ADAS Systems • Other LV Systems
Junction Box 1
Combustion Engine
Generator
Contactor
DC AC Inverter
A/C Compress
or
DC DC Converter
Electric Power Steering
Junction Box 2
6 Confidential and Proprietary | Littelfuse, Inc. © 2017 6 Confidential and Proprietary | Littelfuse, Inc. © 2017
Increased EV Battery Safety Requirements Sensing and Balancing Lines
FMVSS 305 Described: Retention of propulsion battery protection during a crash Added: Electrical isolation of the chassis from the high-voltage system
Protection for the signal line harness
ISO26262 Functional safety for automotive electronics and electrical safety-related systems
OC/OV Protection
R filter
R Discharge
R filter
R Discharge
Passive Cell Balancing
Fuse
Fuse
Vp
Cd
Cm
Cm
Fuse
Cd
ASIL C or D Automotive Safety integrity level
7 Confidential and Proprietary | Littelfuse, Inc. © 2017 7 Confidential and Proprietary | Littelfuse, Inc. © 2017
BMS “Decentralized Architecture” with High and Medium Voltage Fuses
IC Sense/Balancing
line “Slave”
Module N 32
Vdc
to 1
25V
dc o
r hig
her
Module 1
CPU “Master”
Long wires interconnecting cells and slave board ⇒ High likelihood to get short circuit under high voltage in case of crash
event inside module but also between modules Littelfuse Solution ⇒ Fuse in wire: 275A/251A Series Pico Fuse /477A Series Cartridge fuse ⇒ SMD Fuse: 477A Series
Bat
tery
Pac
k Vo
ltage
~4V
8 Confidential and Proprietary | Littelfuse, Inc. © 2017 8 Confidential and Proprietary | Littelfuse, Inc. © 2017
BMS “Centralized Architecture” with Low Voltage SMD Fuse
IC Sense/Balancing
Line “Slave”
Module N 32
Vdc
to 6
3Vdc
Module 1
CPU “Master”
Short distance between cells and slave board ⇒ Low likelihood to get short circuit under high voltage in case of crash
event. However, short circuit on slave board might occur inside the module due to component failure mechanism (capacitor, resistor … )
Littelfuse Solution ⇒ SMD Fuse: 437A /440A Series
Bat
tery
Pac
k Vo
ltage
PCB
~4V
9 Confidential and Proprietary | Littelfuse, Inc. © 2017 9 Confidential and Proprietary | Littelfuse, Inc. © 2017
Littelfuse Sensing Line Auto grade overcurrent protection based on AEC-Q200 standard
Series Technology Form Factor Package Breaking capacity
Voltage Rating
Current rating
437A 440A
TFF 1206 SMD 50A 32Vdc – 63Vdc
2A – 8A
477A Cartridge 5x 20 SMD 400A-1500A
400Vdc 2A-20A
477A Cartridge
5x20 Fuse in cable
400A – 1500A
400Vdc 2A-20A
251 * Pico Fuse
7,11x 2,8mm Fuse in cable
300A 125Vdc 2A-10A
* AEC-Q200 pending for Pico 251 Series and released in March 2017 for 477A Series.
Suitable for Passive and Active Balancing
10 Confidential and Proprietary | Littelfuse, Inc. © 2017 10 Confidential and Proprietary | Littelfuse, Inc. © 2017
Sensing and Balancing Lines Voltage rating vs. size and breaking capacity
Breaking Capacity Size
Voltage
1206
2,8 x 7,1mm in line leaded fuse
63Vdc
125Vdc
400Vdc 5x 20mm SMD
5x 20mm in line leaded fuse
437A/440A Series
Pico 251 Series * 477A Series
50A 300A 500A 1500A
* AEC-Q200 pending for Pico 251 Series
Suitable for Passive and Active Balancing
12 12 12 Confidential and Proprietary | Littelfuse, Inc. © 2017 12 Confidential and Proprietary | Littelfuse, Inc. © 2017
Battery Management System and Protection Devices
440A/437A Series
251 Pico or 477A Cartridge Series
TPSMA6L/SD05
SM24CAN Series
TPSB Series
SPHV_C Series HC HEV fuses
13 Confidential and Proprietary | Littelfuse, Inc. © 2017 Confidential and Proprietary | Littelfuse, Inc. © 2017 13
*Sense Line Fuses: *传感器线路保险丝: Sense Line Short Circuit Protection with electronic fuses can have very different requirements and not all fuses might be suitable. Littelfuse offers a variety of special tested electronic fuses for sense line applications. Please contact your Littelfuse sales or FAE for more details. 使用电子保险丝进行传感器线路短路保护具有非常不同的要求,并非所有保险丝都能适合。力特为传感器线路应用提供各种各样经过测试的特殊的电子保险丝。欲知详情,请联系力特销售或现场应用工程师。
Littelfuse Protection Portfolio
437A 440A Series (SMD)
SP3030 Series
SP4021Series
SM24CAN Series
SPHV_C Series
0HEV Series
1
2
3
4 5 Sense Line Fuse Options* 传感器线路保险丝产品选择*
Cell Monitor IC Input OV Protection 电池监测 IC 输入过电压保护
OV / ESD Protection for Daisy Chain I/F 菊链 I/F 过电压/ESD 保护
OV / ESD Protection for CAN Bus I/F CAN 总线 I/F 过电压/ESD 保护
High Voltage / Current Power Line Fuses 高电压/电流电力线保险丝
6 High Voltage TVS Transient Protection 高电压 TVS 瞬变保护
SD05C Series
* 251 Pico Fuse Series (in line)
477A Series in line with harness or SMD
TPSMx Series
700Vdc/~250A
500Vdc/~125A
450Vdc/~40A- 275Vac/50A
ISO 8820 compliant
AEC-Q compliant * Pending
AEC-Q101compliant
Battery Management System and Protection Devices
L50QS
L70QS
14 Confidential and Proprietary | Littelfuse, Inc. © 2017 Confidential and Proprietary | Littelfuse, Inc. © 2017 14
High Voltage Battery System Littelfuse Protection Portfolio – Selection Criteria
453 Serie
505 Series
• Voltage range depends on battery configuration, same for interrupt rating
• High temperature range >105oC
• Fuse should have a low temperature de-rating
• Low tolerance of cold resistance as well as long term stability is required
• Fuse should be able to cope with temperature cycles and vibrations
• Small Form factor for centralized architecture
• Ideally fulfills AEC-Q test conditions
• LF recommended: 440A Series, 437A Series, 477A Series, Pico 251 Series *)
• Package: SMD, in line, Radial leaded
• Voltage range depends on battery configuration
• Low leakage current • Power requirements
depend on transient environment and battery configuration
• LF offers 600W up to 3000W Diodes
• AEC-Q101 qualified
• Small form factor like TPSMA6L (Low Profile 600W Diode)
• LF recommended: TPSMA6L, TPSMB with stand off voltage range up to 550V
• Typical operating voltage of CAN Bus protectors is 24V
• Power rating between 200W to 500W
• ESD Contact Capability of 30kV recommended
• Low capacitance between 11 to 30pF
• AEC-Q101 qualified
• Small Formfactor Packages SOD882 or SOT23-3 (2 channels)
• LF recommended: SM24CANA, SM24CANB, SPHV-C Series
• Operating voltage up to 1000VDC
• Low current fuse ratings 10A to 30A, 40A (420/450Vdc VDC)
• Medium current ratings 60A to 125A
• High current ratings 150A to 250A
• Form Factors 10x38, 42x20, 52x30
• High Interrupt Rating of 10kA
• Various mounting options: board mount, bolt down, blade, inline cable
• LF recommended: 0HEV/L50QS and L70QS Series (available) Medium / High Current Versions under development
• Following ISO8820-8 Requirements
• 5V Operating Voltage seems to be most common
• Low Capacitance is desirable
• Low leakage current
• Silicon Diode Arrays provide fastest protection and lowest clamp voltages
• Small Form factors of 0402 to 0603
• Power Capability several 10 to several 100W (8/20µs)
• AEC-Q101 qualified
• LF recommended: SP3030, SP4021
1 2
3 4
5 Sense Line Fuse Cell Monitor IC Input OV Protection
OV / ESD Protection for Daisy Chain
OV / ESD Protection for CAN Bus I/F High Voltage / Current
Power Line Fuses 6
High Voltage TVS Transient Protection
*Sense Line Fuses: *Sense Line Short Circuit Protection with electronic fuses can have very different requirements and not all fuses might be suitable. Littelfuse offers a variety of special tested electronic fuses for sense line applications. Please contact your Littelfuse sales or FAE for more details
16 Confidential and Proprietary | Littelfuse, Inc. © 2017 Confidential and Proprietary | Littelfuse, Inc. © 2017 16
EV Chargers and WW Standards
Charging Station UL 2594, GB/T 18487x, SAE J2293, IEC 61851. On Board Battery Charger
SAE J2894,IEC 61851,QC/T 895, GB/T 19751
On-/Off-Board Battery Charger UL 2202
Charging inlet
IEC 62196 UL 2251
SAE J1772 Charging Plug
IEC 62196 UL 2251
SAE J1772
Littelfuse experts provide guidance and support customers’ designs in accordance with worldwide automotive safety standards.
17 Confidential and Proprietary | Littelfuse, Inc. © 2017 17 Confidential and Proprietary | Littelfuse, Inc. © 2017
EVSE to the Grid AC Charging (Slow charge) :
– Level 1: 120V, Single phase 2kW and below Typically takes 8-12 hours to charge fully depleted battery
– Level 2: 208-250V, Single phase (3,3kW ~20kW) Requires a 40A circuit; takes 4-6 hours typically to charge up fully depleted battery
– Level 3: 380V~440V, 3-phase (~20kW) Requires a 30A circuit; takes 4-6 hours typically to charge up fully depleted battery
DC Charging: (Quick charge) – INPUT: 480VAC, 3-phase – OUTPUT: 500VDC~1000VDC, 80A~250A, 100kW + – Typically provides 80% charge within 30 minutes
18 Confidential and Proprietary | Littelfuse, Inc. © 2017 18 Confidential and Proprietary | Littelfuse, Inc. © 2017
On-Board vs. Off-Board Charger On-Board Charger Off-Board Charger
~20kW ~3,3kW ~7,7kW ~2kW ~100kW
Battery charge is managed by BMS Low power transfer Less concern on Battery thermal management Adds weight to vehicle Slow charge
High power transfer More complex BMS to ensure battery thermal management Removes weight from vehicle Fast charge
Power
+ AC/AC
Charging Station AC/DC
Converter AC/DC
Charging Station
19 Confidential and Proprietary | Littelfuse, Inc. © 2017 19 Confidential and Proprietary | Littelfuse, Inc. © 2017
AC Charger Level – On-Board (Single-Phase)
Rectifier PFC DC/DC converter OC/OV OC/OV OC/OV
Input Voltage
PFC Link
Output Voltage
EMI Filter
P
N
PE
Overvoltage: Varistor: AUMOV Series (AEC-Q200 March 2017), GDT: CG3 Series Overcurrent: 0HEV (ISO8820-1), 525A Series* * AEC-Q200 pending. Please contact your Littelfuse sales or FAE for more details.
120Vac/220Vac 500Vdc
AC
AC Cab
le
Stationary base
In Vehicle
or
20 Confidential and Proprietary | Littelfuse, Inc. © 2017 20 Confidential and Proprietary | Littelfuse, Inc. © 2017
AC Charger Level – On-Board (3 phase)
Rectifier PFC DC/DC converter OC/OV OC/OV
PFC Link
Output Voltage
EMI Filter
N
PE
Overvoltage: Varistor: AUMOV Series (AEC-Q200 March 2017), GDT: CG3 Series Overcurrent: 0HEV (ISO8820-1), 525A Series* * AEC-Q200 pending. Please contact your Littelfuse sales or FAE for more details.
380Vac 500Vdc
AC
AC
Stationary base
In Vehicle
OC/OV
Input Voltage
P3
Or
P2 P1
Cab
le
21 Confidential and Proprietary | Littelfuse, Inc. © 2017 21 Confidential and Proprietary | Littelfuse, Inc. © 2017
DC Charger – Off-Board (~ 100kW + / 3 Phases) Single 1x 100kW and modular structure 4x 25kW
Rectifier PFC DC/DC converter OC/OV OC/OV OC/OV
Input Voltage PFC Link
Output Voltage
EMI Filter
P1
N
PE
Overvoltage: MOV: AUMOV Series (AEC-Q200 March 2017) and TMOV, GDT: CG3 Series Overcurrent: Charger with Monolithic structure: L50QS and L70QS Series Charger with Modular structure: 504 Series, 505 Series Please contact your Littelfuse sales or FAE for more details.
P2 P3
Or
380Vac -480Vac 500Vdc 700Vdc
23 Confidential and Proprietary | Littelfuse, Inc. © 2017 23 Confidential and Proprietary | Littelfuse, Inc. © 2017
DC/DC Converter Protection
DC/DC converter
Overvoltage: TVS: TPSMx Series (AEC-Q101 qualified) Please contact your Littelfuse sales or FAE for more details.
500Vdc PFC Link
IGBT/FET Gate Overvoltage Protection
or
Single TVS or Stack of TVSs for IGBT active clamping voltage feature
Ic Vdc
Vclamp
Vce
Vdc
Vce
time
24 Confidential and Proprietary | Littelfuse, Inc. © 2017 24 Confidential and Proprietary | Littelfuse, Inc. © 2017
IGBT/ MOSFET Driver Protection
Inpu
t Log
ic
PWM HS
GND
PWM LS
Vcc
Enable
µController
Vdd
HV DC link
Vdd
Vss
Input Logic: Diode Array SPx Series (AEC-Q101 qualified) Power Supply: MLA & AUML Series (AEC-Q200 qualified), TVS TPSMx Series (AEC-Q101 qualified) Gate Protection, Negative bias voltage: TVS TPSMx Series (AEC-Q101 qualified)
Cb
25 Confidential and Proprietary | Littelfuse, Inc. © 2017 Confidential and Proprietary | Littelfuse, Inc. © 2017 25
High Voltage EV Charger Littelfuse Protection Portfolio
SP Series SM24CAN Series
TVS TPSMxx Series
0HEV Low Current
L50QSMedium Current *
L70QS High Current *
Varistor AUMOV Series TMOV Series*
MLV AUML Series
ESD
ISO 8820 compliant AEC-Q pending
L50HS Series
* Please contact your Littelfuse sales or FAE for more details.
On-Board Charger Off-Board Charger
* GDT CG3 Series
Overcurrent Protection Overvoltage Protection
On- and Off-Board Charger
525A Series *
AEC-Q101qualified
AEC-Q101 qualified AEC-Q200 (March 2017)
AEC-Q200 qualified
450Vdc/~40A- 275Vac/50A
500Vdc/~125A
700Vdc/~250A
450Vdc ~ 30A 500Vac/420Vdc ~ 30A
500Vdc/Vac ~800A L70HS Series
700Vdc/Vac ~800A
504A Series
505A Series 500Vac/500Vdc ~ 30A
Only Off-Board Charger
26 Confidential and Proprietary | Littelfuse, Inc. © 2017 26 Confidential and Proprietary | Littelfuse, Inc. © 2017
Summary and Conclusion The market for vehicles using any kind of electric, battery-powered drive system with voltages equal to or
higher than 48V is expected to grow by double digits in the coming years.
Lithium-based battery technology will be the basis for any kind of xEV vehicles; in addition to its advantages of power density and charging cycle life, it requires major efforts in monitoring and protection.
Battery Management Systems in xEV vehicles are highly complex and mission-critical systems that need to be properly placed and selected protection components for overvoltage and short circuit protection.
Electronic fuses for usage in vehicle systems like BMS Sense Line Protection need to be selected carefully and should be able to pass reliability testing following the AEC-Q guidelines; consultation with fuse experts from Littelfuse is essential.
On-Board Charging Systems link closely with the BMS system of a vehicle and also require a high level of short circuit and overvoltage protection for AC and DC power systems, meeting automotive grade Reliability Expectations in terms of temperature, vibration and transient robustness.
Littelfuse provides guidance and support customers design according to worldwide automotive safety standards – Please contact your Littelfuse local expert!
27 Confidential and Proprietary | Littelfuse, Inc. © 2017 27 Confidential and Proprietary | Littelfuse, Inc. © 2017
Global Footprint – R&D, Manufacturing & Support
Americas 1. Chicago, Illinois, USA (S) 2. Bellingham, Washington, USA (S) 3. Boston, Massachusetts, USA (S, RD) 4. Champaign, Illinois, USA (RD) 5. Lake Mills, Wisconsin, USA (S, RD) 6. Mount Prospect, Illinois, USA (RD) 7. Rapid City, South Dakota, USA (S, RD, M) 8. Fremont, California, USA (RD) 9. Troy, Michigan, USA (S) 10. Manaus, Brazil (S) 11. São Paulo, Brazil (S) 12. Saskatoon, Canada (S, RD, M) 13. Matamoros, Mexico (M) 14. Muzquiz, Mexico (M) 15. Piedras Negras, Mexico (RD, M)
Europe 16. Bremen, Germany (S, RD) 17. Essen, Germany (S) 18. Lauf, Germany (S) 19. Legnago, Italy (RD, M) 20. Ozegna, Italy (RD, M) 21. Kaunas, Lithuania (RD, M) 22. Amsterdam, Netherlands (S) 23. Deventer, Netherlands (S)
Asia 24. Beijing, China (S) 25. Dongguan, China (RD, M) 26. Hong Kong, China (S) 27. Kunshan, China (S, M) 28. Shanghai, China (S, RD, M) 29. Suzhou, China (S, RD, M) 30. Wuxi, China (RD, M) 31. Tokyo, Japan (S) 32. Tsukuba, Japan (RD, M) 33. Seoul, Korea (S) 34. Lipa City, Philippines (RD, M) 35. Singapore (S) 36. Chu-Pei, Taiwan (RD) 37. Taipei, Taiwan (S)
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S–International Sales RD–Research & Design M–Manufacturing
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