Complete system solutions for e-mobility applications
Michael Lütt Rutronik Digital Automotive Forum Agenda
1 Electric Vehicles (EV) classification and key applications
Traction inverters, DC/DC converters, on-board chargers (OBC), and battery management 2 systems (BVMS)
3 Key product families for e-mobility: STPOWER, Smart Power Solutions, 32-bit MCUs
4 Silicon Carbide (SiC) value proposition for e-mobility
2 ST is making driving greener
Vehicle Electrification
What Electrification Means Product Use of electric power to replace some or all of the propulsion requirements of a vehicle
3 Electric Vehicles Classification
Electric Vehicles can be classified by the degree to which electricity is used to power the vehicle
Hybrid Electric Vehicles (HEVs) Plug-in Hybrid Electric Vehicles (PHEVs) Battery Electric Vehicles (BEVs)
100%
4 Industry challenge: making driving greener ST offers a complete range of solutions for all segments
Internal Combustion Engine Mild Hybrid 48V Battery Electric Vehicle Low-end entry level electrification High-end battery-based full electric car
Reducing emissions International CO2 target Moving towards electric vehicles
Euro4 vs. Euro6
(*) ~65% less NOx ~15% less CO2 Emission-free
Lower Emissions and Increasing Semiconductor Content
Euro4, Euro6 : European Emission standards for passenger cars and light commercial vehicles 5 (*) European emission standards referred to diesel passenger car (Euro4 vs. Euro6) Key applications in EVs
Trends
400V → 800V Traction 5-250kW 48V LV/MHEV Inverter IGBT → SiC
On-board 100kHz → 1MHz 7-22kW Charger Si → SiC & GaN
DC/DC 4-10kW 100kHz → 1MHz converter Si → SiC & GaN
Battery 400V → 800V 8-14 cells Management 48V LV/MHEV
6 ST Value
Silicon Carbide Vertical integration Traction inverter leadership
The traction inverter converts energy from the vehicle’s battery to drive the motors in the drivetrain. This key component has a direct impact on road performance, driving range and reliability of the vehicle also as a consequence of its weight and size.
Subject to intense heat and vibration of the automotive environment, these converters must be able to handle high power and currents along with associated Electro Magnetic Compatibility (EMC) challenges.
Fail-safe operation needs to be assured to ensure reliability and safety for the driver and passengers.
Key trends
• Varied approach by region • Strong move to 800V bus • Discrete approach • New kind of motor & speed & position sensor entering the market • AI Predictive Maintenance & security ecosystem to be introduced
7 ST Value
World-class Expertise in In-house M5 and DM6 power Manufacturing On-board charger (OBC) technology conversion capability
At the heart of any electric (EV) or plug-in hybrid (HEV) vehicle lies the high-voltage (200 to 800 VDC) battery and its associated charging system.
The on-board charger (OBC) provides the means to recharge the battery from the AC mains either at home or from outlets found in private or public charging stations.
From a 3.6 kW single-phase to a 22 kW three-phase high-power converter, today’s OBCs must have the highest possible efficiency and reliability to ensure rapid charging times as well as meet the limited space and weight requirements. Key trends
• Active PFC with SiC bridge • 7kW-11kW common in RFQs • Bidirectional OBC function • Aux DCDC in same housing • 650V GaN to miniaturize and simplify bidirectional OBC (1 MHz) • HV DC fast charging everywhere, PFC block usage will decrease
8 ST Value
World-class In-house Expertise in DC/DC converter DM6 fast-diode Manufacturing power conversion technology capability
Electric vehicles (EV) use two different power systems; a high-voltage battery (200 to 800 VDC) for traction and a low-voltage (12/48V) one for supplying all the electric appliances in the vehicle.
Traditionally, the low-voltage battery was charged from the alternator, but in today’s vehicles it gets its power from the high-voltage battery pack. However, in specific electric car architectures, this low voltage battery should be ready to help recharge the high-voltage battery pack in order to provide energy for cranking the car.
This means that the on-board DC-DC converter must be bi-directional and very efficient as well as highly reliable in order to run the complex control algorithms needed to ensure an energy-efficient solution.
Key trends
• Market for 800V increasing • Bidirectional operation • Direct control of PWM from MCU • Move to GaN particularly for LV DC-DC • Integration into OBC
9 ST Value Battery Management ASIC & ASSP BCD9SL Manufacturing expertise technology capability
1st BMS development started in 2008 Key trends
• Progressive shift to 800V 1st BMS in system mass production • 48V BMS applications since 2011 • New partitioning schemes due to new Li chemistries • Single-cell battery monitoring • Periodic wakeup & reporting
10 Automotive battery management system …and the peripheral functions
Emergency Cut-Off
HV+
CSE(n) u Squib ... Vehicle bus System Basis Driver VCU Communication & Companion
CSE(n-1) v w
HV Relay ... Control
B6 MCU + ...... Driver SBC Micro- Power Controller Isolated (MCU) CSE(0) Distribution SPI Transceiver Current Sense Thermal Solution ... Management (not strictly part of BMS system)
Shunt / Hall HV- HV switch Current Control unit Sense 11 Automotive battery management system
L9963 and L9963T evaluation platform
EVAL-L9963-MCU • Evaluation and development platform for 48V battery • Fast prototyping and evaluation of L9963 and L9963T • Voltage, current and temperature sensing up to 14 cells • Scalable approach with additional EVAL-L9963-NDS for higher battery voltages • Including SPC57 Microcontroller with preloaded firmware
EVAL-L9963-NDS • Add-on board for higher battery voltages up to several 100V • To be stacked on EVAL-L9963-MCU
EVAL-L9963 • Evaluation platform for SW development with an alterative external MCU
12 Key product families for e-mobility
• STPOWER and Discretes • Smart Power Solutions • 32-bit Automotive MCUs STPOWER and Discretes The success factor in the fast growing EV market
HV MOSFETs Today’s Offer and Roadmap IGBT Solutions ST commitment
Extending offer on Traction, OBC and DC-DC: Investing in new DM2 DM6 Higher Efficiency Facilities to sustain STGWA60V60DWFAG IGBT with SiC co-packed diode STGST200G65DFAG Coming in ACEPACK* SMIT Power Silicon K5 K6 Higher Voltage Range solution growth
M5 M9 More Power Density Narrow Mesa technology Agrate Fab
Continue innovation PowerFLAT ACEPACK* on Power Package 8x8 HV SMIT 300mm TO-LL HU3PAK
Protection & TVS Rectifier & SCR / Triacs
▪ DC/DC with TVS series Very Large portfolio including new ▪ OBC input Protection TN3050H & TN5050H for 30A & 50A Extending capacity for ▪ MOSFET/IGBT Protection with 150°C max junction SiC & MDmesh* ▪ BMS Protection and to support Doubling Protection content in EV Car (~7$) Over 10$ per EV of SCR & Rectifiers Narrow Mesa roll-out
* is a registered and/or unregistered trademark of 14 STMicroelectronics International NV or its affiliates in the EU and/or elsewhere. STPOWER SiC MOSFET The enabling technology for electric vehicles
Silicon Carbide product portfolio Main applications
Automotive grade 650V SiC MOSFETs OBC 2nd generation High-Voltage Product Family Traction Inverter
• SCTx35N65xx • SCTx100N65xx
HiP247 H2PAK-7 HiP247 long leads DC/DC converter
Automotive grade 1200V SiC MOSFETs Key benefits 2nd generation Very-High-Voltage Product Family • Higher power density • Smaller form factor • SCTx40N120xx • Higher system efficiency at high frequency • SCTx70N120xx • Reduced size/cost of passive components • SCTx100N120xx • Low power losses at high temperatures HiP247 2 HiP247 H PAK-7 long leads 15 Power modules Standard & custom solutions targeting specific needs
Wide ranging module portfolio Standard & custom system solution ACEPACK* ACEPACK* 1 ACEPACK* DRIVE SMIT STANDARD portfolio Plug&Play Module for ACEPACK* 2 Traction inverter, On-Board Charger and DC-DC converter
Silicon and SiC technologies portfolio CUSTOM solutions Combining semiconductor and BCD package technologies addressing multiple design topologies tailored to specific Si & SiC Si & SiC customer needs IGBT Smart Power Diodes MOSFET
* is a registered and/or unregistered trademark of 16 STMicroelectronics International NV or its affiliates in the EU and/or elsewhere. Smart Power Solutions for Electrification extending our product offer and application coverage
Battery Management System Isolated Driver for IGBT & SiC MOSFETs
ST Modular solution supporting ISO 26262 : Functional Safety solution up to ASIL-D Compliancy Electrical mobility from 48V up to 800V With a portfolio with multiple options
L9963 and L9963T L9501 Series L9502 Series
• Flexible and affordable solution • Best in class cells voltage accuracy BCD9sL • Synchronous cells voltage acquisition BCD6s(*)
Twin Isolated Gate Driver (6kV) Single Isolated Gate Driver (6kV) For OBC, DC/DC, BSG For Traction
Emerging EV domains: Battery Cut-Off & Fire-off 48V Electric Motors (MHEV and others) Battery Cut-off: Interrupt battery line in case of crashes L9907 L9908 Battery Fire-off: Extinguish possible fire condition • MHEV • Motorbike L9678 & L9679 • E-bike • Forklifts System basis chip for squib driver Full production by H1 2021
17 (*) With Galvanic Isolation SPC5 32-bit Automotive MCU
Performance - Safety critical ASIL D 400MHz 16MB General Purpose - Body & Gateway SPC58 H HW Security 200MHz, 3x z4 QFP144/176 10MB BGA292/376 Stellar Family 28nm ASIL D ASIL D ASIL D SPC58 E SPC58 N SPC58 G 6MB ARMv8-R Cortex-R52 200MHz 180MHz, 3 x z4 200MHz, 3x z4 180MHz, 3x z4 6x core SPC564A QFP176 QFP176 QFP144/176 Up to 400MHz BGA292 KGD BGA292 KGD BGA292 150MHz, z4 4MB 180MHz QFP176/BGA324 SPC58 C PCM: up to 40MB SPC56 4B/EC ASIL D ASIL D SPC57 K 180MHz, 2x z4 Package: BGA516 sampling 3MB 120MHz, z4+z0 SPC56 L 160MHz, z4+z2 QFP64/100/144/176 QFP176/208 BGA292 120MHz, 2x z4 BGA256 QFP144/176 KGD ASIL D SPC58 4B 120MHz QFP100/144 SPC57 2L SPC57 4S 2MB 120MHz, z4 SPC56 M 80MHz, z2 140MHz, z4 QFP64/100/ SPC56 0B+ 80MHz, z3 QFP80/100 QFP100 144/176 R52 64MHz, z0 QFP144/176 ASIL D SPC58 2B 1MB QFP100/144/176 80MHz SPC57 0S 80MHz, z2 SPC56 AP SPC56 0B/0C 80MHz, z0 QFP64/100
64MHz 64MHz, z0 QFP64/100 Resources & Performance & Resources 64MHz, 2x z0 QFP64/100/144 512k QFP100/144
SPC56 P SPC56 D Extended functionality and increased performance 64MHz, z0 64MHz, z0 2nd Generation+ products recommended for new designs 48MHz 128k QFP64/100/144 QFP64/100 st nd rd 1 Generation 2 Generation 3 Generation 18 Silicon Carbide (SiC) value proposition for e-mobility Silicon Carbide (SiC) history
More than 20 years of SiC history in STMicroelectronics
Silicon carbide was Henri Moissan 1949-1951 Frank 1958 First SiC discovered by Edward discovered SiC grains in developed the screw conference held in G. Acheson in 1891 the Diablo Canyon iron dislocation theory of Boston, USA. He named it Carborundum meteorite polytypism 1891 1905 1951 1958
October 2007 May 2012 September 2014 February 2003 1st Gen Diode 2nd Gen Diode 1st Gen MOSFET ETC Epitaxial Start Production Start Production Start Production reactor prototype installed in ST
June 1996 May 2004 March 2009 June 2014 June 2017 Collaboration with Schottky Diode Power MOSFET 3rd Gen 3 Diode 2nd Gen MOSFET Physics Dept. Demonstrator 3" Demonstrator Start Production Start Production 1996 1998 2000 2002 2004 2006 2008 2010 2012 2014 2016…
20 Car Electrification boosts the power content
Powertrain TAM Evolution SiC MOSFET versus IGBT advantages in a traction inverter
IGBT, Si MOSFET and SiC MOSFET will co- Electric car motor and inverter exist for several years in automotive market • Higher power density • Size and weight 2023 2018 ~60% <50% reduction Other Si Other Si • Direct inverter integration % % IGBT SiC MOSFET • Higher efficiency ~40 >50 inverter inverter Power Power Potential saving thanks to SiC MOSFETs
2018 SiC 2023 SiC MOSFET MOSFET $ +300 $ Sic MOSFET Additional Cost (*) ~2000 MOSFET Estimated Saving (*) IGBT IGBT (*) Source: Goldman Sachs
ST has the full technology and product offer to support both solutions 21 SiC MOSFET value proposition
SiC MOSFET vs silicon IGBT SiC Advantages for Automotive
Electrification => range extension vs. smaller battery, size and Higher performance & voltage weight reduction, less cooling requirements operation • Extremely low power losses Efficiency Switching Switching • Higher efficiency at low-medium Chip size Total loss currents gain losses frequency • Intrinsic sic body diode From ~2% ~7x lower ~5x smaller ~50% lower ~ 5 ...10 times Higher operating frequency (high load) higher • Excellent diode switching performance to ~10% (low load) • Lower switching losses Lower System Cost Higher operating temperature • Operating up to 200°C junction Smaller passives, no ~7x reduced form ~80% cooling system external freewheeling factor downsizing diodes
22 SiC Diodes Improving power conversion efficiency
Silicon ultrafast diodes Sic diodes More efficient power conversion
Power losses Eliminate recovery losses Reduced dimensions - 60%
Switching performance comparison
Sic diode SiC
Stpscxh065
Current Efficiency Time Recovery Conduction Si % @low load losses losses 600V ultrafast silicon based +20AVG
Power
Energy savings generated by a sustainable technology
23 Thank you
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