power electronics for e-mobility applications - · pdf filepower electronics for e-mobility...

Power Electronics for e-MOBILITY Applications

Karlsruhe, 2016-09-07

Dr. Andreas Docter, Director eDrive Components, Daimler AG

Dr. Marcus Heller, Senior Manager eMotor and Power Electronics, Daimler AG

Daimler – 5 Business Fields

Mercedes-Benz

Cars

Daimler

Trucks

Daimler

Buses

Mercedes-Benz

Vans

Daimler Financial Service

Power Electronics for e-MOBILITY Applications, Dr. Andreas Docter, Dr. Marcus Heller, EPE 2016 2

Daimler‘s Vision of Future Mobility


Electrified Daimler Fleet


Electrification of a Conventional Powertrain


H2 + + + + +

Power of Electric Motor

Degree of Electrification

Conventional Vehicle Electric Vehicle

Electric Driving Range

Micro-Hybrid

Start-Stop

Mild-Hybrid Full Hybrid

(HEV)

Plug-In Hybrid

(PHEV)

Range

Extender

(RE BEV)

Battery Electric Vehicle

(BEV)

Fuel Cell Electric Vehicle

(FCEV)

12 V 12 V / 48 V 140 V 280 – 420 V 280 – 420 V up to 470 V up to 470 V

2 km 20 - 80 km 50 – 120 km 80 – 500 km 400 – 600 km

10-20 kW 30-50 kW 50-100 kW 50-150 kW

0% 100%

Scheme of an Electrified Powertrain


EM DC

AC

AC

DC

DC

DC

G

Charger Battery DC/DC Inverter E-Motor Gearbox

Requirements for Electric Powertrains


€ Electric Driving

Range Performance Costs Charging Time Agility Service Reliability NVH NVH

Product Strategy of Electrified and Zero-Emission Vehicles

48V Hybrids Plug-In Hybrids

Battery Electric Vehicles &

Fuel Cell Electric Vehicles

Power Electronics for e-MOBILITY Applications, Dr. Andreas Docter, Dr. Marcus Heller, EPE 2016

48 V Hybrids Under Development

• MOSFET-Technology

• DC-Link Voltage: 48 V

• Maximum Phase Current: 500 A

• Maximum Electric Power: 15 kW

Integrated Starter

Generator

Power Pack Belt Starter Generator


8 Plug-In Vehicles Already Launched

Hybrid Drive Train C350e Plug-In Hybrid

• DC-Link Voltage: 410 V

• Maximum Phase Current: 300 A

• Maximum Electric Power: 60 kW / 85 kW

• Electric Range: 35 km


0

Electric Vehicles

• Battery Electric and Fuel Cell Electric

• Electric Power : sufficient

• Electric Range: approx. 500 km


1

Mondial de l Automobile 2016, Paris

Power Electric Components in Vehicles

DC/DC-

Converter

Onboard-

Charger

DC/AC-

Inverter

E-Motor Battery


2

Inverter Characteristics for Automotive Use


3

…

…

E-Motor Type

that can be operated

Power Density

(Volume and Weight)

Power Efficiency Costs

Ambient Temperature

and

Vibration Stability Integration

with E-Motor

and Gearbox

EMC

Inverter

Ways to Increase Inverter Power

New

1200 V

IGBTs

New

900 V

IGBTs A

800 V

600 V

400 V

200 V

0 100 A 200 A 300 A 400 A 500 A 600 A 700 A

200 kW

160 kW

120 kW

80 kW

15 kW

B

C

State

of the

Art

650 V

IGBTs

DC-Current

DC

-Lin

k V

olt

age

Power scaling up to 200 kW by increased

voltage (A), increased current (C) or

combination of both (B)

100 V

MOSFETS

48 V Hybrid


4

PHEV

Progress in Development of Inverters

AC

DC

Year of SoP 2009 2012 2014 2016 2020 > 2025

Power Density 100 % 160 % 175% 185% more even more

Volume 4.1 l 3 l 3.8 l 3.3 l less even less

𝑈DC,max 390 V 405 V 410 V 410 V more even more

𝐼Ph,10s,max 215 A 240 A 325 A 300 A more even more

2009 2012 2014 2016 2020 >2025

Pow

er

Den

sity

(n

orm

) 300%

200%

100%


5

Desired Development of Inverter Components

Gate

Drivers

Control

Board

Cooling

Safety

Functions

Contacting

Semi-

conductors

Capacitor


6

Desired Development of Volume of Inverter Components

20%

> 2025

17%

11%

14%

8%

8%

8%

17%

23%

2016

5%

-30%

Capacitor

Semiconductors

Cooling

Contacting

Gate Drivers

Safety Functions

Control Board 5%

10%

10%

15%


7

Inverter Integrated Hybrid Drive System

AC-Cables

No need for AC-Cables: Integration of Inverter, E-Machine and Gearbox

Electric Drive Train of SmartEV Electric Drive Train of Future EV

DC-Cables


8

Importance of Overall-Efficiency of Electric Drivetrain


…

…

Carbon

Footprint

Electric

Range

Maximum

Power

Total Cost

of

Ownership

Cooling

Capacity Certification

Overall-

Efficiency

Cost Trend for Electric Drive Train

20 Source: Department of Energy

2012 Electric Drive System $30/kW, 1.1kW/kg, 2.6kW/L

90% system efficiency

(on-road status) • Discrete Components

• Silicon Semiconductors

• Rare Earth Motor Magnets

2022 Electric Drive System $8/kW, 1.4kW/kg, 4.0kW/L

94% system efficiency

(on-road status) • Fully Integrated Components

• Wide Bandgap Semiconductors

• Non-rare Earth Motor


4x Cost Reduction

35% Size Reduction

40% Weight Reduction

40% Loss Reduction

Daimler AG

Standardized Connector

DC/DC

Converter

Integration in Axle

Future Requirements for Power Electronics

21

DC/AC

Inverter

Onboard

Charger

Power Electronics for e-MOBILITY Applications, Dr. Andreas Docter, Dr. Marcus Heller, EPE 2016

THD Modular

and Scalable

Power Density

Losses

Daimler AG

• New Semiconductor Materials

(SiC, …)

• New Hardware Topologies

(Multi-Level, …)

• New Safety Concepts

Power Density

Losses

DC/AC

Inverter

Onboard

Charger

DC/DC

Converter

Future Trend 1: Higher Voltage Levels

22 Power Electronics for e-MOBILITY Applications, Dr. Andreas Docter, Dr. Marcus Heller, EPE 2016

Daimler AG

THD

Losses

DC/AC

Inverter

Onboard

Charger

DC/DC

Converter

• New Semiconductor Materials

(SiC, GaN, …)

• New Passive Components

(Capacitors, Inductances, …)

• Optimized Control Units

(FPGA, ASIC)

Future Trend 2: Higher Switching Frequency

23 Power Electronics for e-MOBILITY Applications, Dr. Andreas Docter, Dr. Marcus Heller, EPE 2016

Daimler AG

Losses

DC/AC

Inverter

Onboard

Charger

DC/DC

Converter

Future Trend 3: High Performance SW Control

• Self-Tuning of Parameters

• Error Prediction, Prevention

and Detection

• Sensorless Control at any

Speed

• Control of Multiphase-

Machines

• High Speed Motor Control Power Electronics for e-MOBILITY Applications, Dr. Andreas Docter, EPE 2016 24

THD

XXX

Electrification is progressing!

power electronics for e-mobility applications - · pdf filepower electronics for e-mobility...

Documents