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2010-01-14 Page 1 Copyright © Infineon Technologies 2010. All rights reserved. Power Semiconductor – State of the Art and Development Trends By Leo Lorenz Infineon Technologies Munich E-mail: [email protected] Focus Application: Power Devices for Automotive & Industry Outline: Indroduction Power Devices & SMART Power IC´s for Automotive Application - SMART Power IC´s - Discrete Power Devices (Power MOSFET, SiC, IGBT´s) Development Trends and Challenges

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  • 2010-01-14 Page 1Copyright Infineon Technologies 2010. All rights reserved.

    Power Semiconductor State of the Art and Development Trends

    By

    Leo Lorenz

    Infineon Technologies

    Munich

    E-mail: [email protected]

    Focus Application: Power Devices for Automotive & Industry

    Outline:

    Indroduction

    Power Devices & SMART Power ICs for Automotive Application

    - SMART Power ICs

    - Discrete Power Devices (Power MOSFET, SiC, IGBTs)

    Development Trends and Challenges

  • 2010-01-14 Page 2Copyright Infineon Technologies 2010. All rights reserved.

    Power Semiconductor State of the Art and Development Trends

    Key Message: The most inexpensive and environmental friendlyenergy is:

    The Energy We Do Not Consume Nor Waste

    Driving Technology:

    Power Devices & SMART Power ICs

    System Integration

    Precise Control of Energy Flow

    Demand oriented operation of load

  • 2010-01-14 Page 3Copyright Infineon Technologies 2010. All rights reserved.

    Nin Nout

    ControlDesired value

    Actual value

    LoadSource

    AC: V, f, j, 1-Phase, 3-PhaseDC: V, +/-

    AC: V, f, j, 1-Phase, 3-PhaseDC: V, +/-

    Very Basic Structure of any Power Electronic System(Inverter, Converter)

  • 2010-01-14 Page 4Copyright Infineon Technologies 2010. All rights reserved.

    Description of SystemsSense Process Actuate in Closed Feedback Loop

    Components of System

    Sensors

    PowerDevices

    Micro-controlle

    r

    Solution

    Components

    eP WL

    LWS

    ACROPOLIS

    Challenges

    Q & A

  • 2010-01-14 Page 5Copyright Infineon Technologies 2010. All rights reserved.

    Energy Consumption and Control of Energyflowthrough Power Electronics

    12 billion kilowatts every hour of day of every year

    20

    Source: CPES/EPRI

    16

    12

    8

    4

    01800 1900 2000 2100 Year

    20 40 60 80 20 40 60 80 20 40 60 80

    Total Energy

    Electrical Energy 30% savings withimproved powerelectronics(components & systems)

    Motor55%

    Internet10%

    Lighting21%

    Other14%

    40%ElectricalEnergy

    Total Energy

    1997: 40%2010: 80%

    60% 20%

    Power Electronics Control Unit

  • 2010-01-14 Page 6Copyright Infineon Technologies 2010. All rights reserved.

    Major Consumers of Electrical Energy Savings Potential

    Source: ZVEI, Siemens, CEMEP, CPES, EPA, NRDC, IFX

    Today: 40% out of the overall energy consumption is electrical energyC

    onsu

    mer

    s el

    ectri

    cal e

    nerg

    y (w

    w)

    Energy Split: ww Energy saving potential

    Key technology

    Power supply:- stand-by, - active,

    - Computing

    EC-BallastDaylight dimmingHID, LED,

    Factory autom.Process engineering,Heavy industry,Light industry,

    Transportation:Train, Bus, Car,

    Home appliance:Freedge, WM,HVAC

    80+ / 90+

    Electronic control

    IGBTModulesCiPOSEMCONCoolMOSCTOptimized C8 bit / 16 bit / 32 bit

    >90%>>1%

    >>1%

    >25%

    >30%

    >25%

    >40%

    CoolMOS, SiCSmart control ICCoolSETLow cost C

    CoolMOSSmart ballast ICLow cost C

    I&COthers

    24%

    Lighting21%

    Motor control55%

    - stand-by- active

    Variable Speed Drive (VSD)

    VSD + Reverse Energy

    VSD

    confidential

  • 2010-01-14 Page 7Copyright Infineon Technologies 2010. All rights reserved.

    Motor drives is about RPM control enablingincrease in overall system efficiency

    Applications

    Invert

    er

    base

    d

    mo

    tor

    The inverter supplies the drive with exactly thepower it needs, minimizing energy losses

    Energy saving of ~ 25-40% is possible

    AC 240-690 V

    Energy grid Inverter &Power Electronic

    Inverter output 3~

  • 2010-01-14 Page 8Copyright Infineon Technologies 2010. All rights reserved.

    Motor Drives: Basic Principle

    Diode Rectifier

    3 x 400V /50HzL1

    L2

    L3

    +

    -

    U[V] U[V]

    IGBT Inverter

    UVW

    U[V] U[V]

    AC voltage

    Fixed frequency 50Hz

    AC-voltage

    variable frequency 0-300Hz

    AC-InputMains AC-Output

    Motor

    DC-Link

  • 2010-01-14 Page 9Copyright Infineon Technologies 2010. All rights reserved.

    History of Power Semiconductors

    IGBT

    Cool-MOS

    MOS-transistor

    GTO

    bipolar transistor

    thyristor

    diode

    400V - 1000V;1A - 50A

    20V - 1000V;1A - 100A

    year

    small power medium power

    197019601950

    voltage range;current range

    200019901980

    600V - 8000V;1A - >1000A

    > 3000V;> 500A

    > 3000V;> 500A

    1000A

    600V - 6500V;1A - >1000A

    GCT

  • 2010-01-14 Page 10Copyright Infineon Technologies 2010. All rights reserved.

    Application for Power Semiconductor Components

    Source: IPEC 2000 Semiconductor switching frequency10 Hz 100 Hz 1 kHz 10 kHz 100 kHz

    Capacity of the converter system

    Reative compensators AC-AC interties1 GW

    100 MW

    10 MW

    1 MW

    100 kW

    10 kW

    1 kW

    100 W

    High current supplies large drives

    Heavy locomotives

    Large solar power plants trams, busses

    Electric cars

    Switched mode power supplies

    Thyristor

    Year 2005Tendency

    GTO

    IGBT

    FET

    Ultra high power

    High power

    Mediumpower

    Low power

    the higherthe converter capacity,the lowerthe switching frequency

    HVDC

    IFX 2136 1099/MCD

  • 2010-01-14 Page 11Copyright Infineon Technologies 2010. All rights reserved.

    Automotive Applications

    New fields:Cam shaft

    replacement,42V/12V DC/DC

    converter

    Starter Generator

    (Ta >150C

    Brake by wire(Ta >150C)

    Steer by wire,intelligent power

    management

    Power seatPowerwindow

    Wiper

    Sun roof

    Gearbox /Clutch

    Enginemanagement

    Climate control

    Starter / FanPower steering

    Headlightbeam control

    Doorlock

    Mirrorcontrol

    Brakes

    SMART Power Bridges 1A < I < 250A_ _

  • 2010-01-14 Page 12Copyright Infineon Technologies 2010. All rights reserved.

    Global CO2 Targets

    It's the law: 35 mpg CAFEAutomotive News Dec. 19th 2007Cars: 35 mpg by 2020

    EU Proposes steep fines to cut car CO2 from 2012Automotive News Dec. 20th 2007Cars: 120gCO2/km by 2012+10 g coming from biofuels

    60.1854.1649.2445.1341.6638.6935.00MPG

    3.914.344.785.215.656.086.72l / 100km

    90100110120130140155g CO2/km

    Conversion table for regular gasoline engine

    90

    100

    110

    120

    130

    140

    150

    160

    170

    180

    190

    200

    1994

    1996

    1998

    2000

    2002

    2004

    2006

    2008

    2010

    2012

    2014

    2016

    2018

    2020

    gC

    O2

    /km

    161 gCO2/km

    130 gCO2/km

    120 gCO2/km

    95 gCO2/km

    OEM Actual

    OEM Voluntary

    Target

    EU Proposal(Dec, 2007)

    Alternative Proposal

    incl. BioFuel(Jan, 2008)

  • 2010-01-14 Page 13Copyright Infineon Technologies 2010. All rights reserved.

    LIN-systems connected via CAN

    System Architecture of Modern Cars A Complex Network of Interacting Sub-Systems

    Source: C. Bracklo, 1st Intl LIN Conf., Sep02

    >9km cables with >100kg for > 70 ECUsHow to manage this complexity at low cost?

    Solution

    Components

    eP WL

    LWS

    ACROPOLIS

    Challenges

    Q & A

  • 2010-01-14 Page 14Copyright Infineon Technologies 2010. All rights reserved.

    Control: 24 lampsSwitched Power:650WDissipated Power: 7W

    Light Control Module : Block diagram

    CHMSL (LED)

    Indicator

    Reverse Tail Indicator Brake Fog

    Park Indicator High Low Fog Interior (dim) Relais Fog Low High Indicator Park

    Indicator

    Spare 5A Foot well

    BTS44316m

    BTS44316m

    BTS44316m

    BTS44316m

    BTS44316m

    BTS44316m

    BTS44316m

    TLE 622516m

    BTS13416m

    BTS7244x90m

    BTS7164x140m

    BTS7244x90m

    BTS7244x90m

    BTS7244x90m

    License Plate Brake Indicator Tail Reverse

    TLE 6258LIN

    TLE 6252CAN

    Vbat

    TLE 42685V LDO

    C164CI

    To rest of car

    To rest of car

  • 2010-01-14 Page 15Copyright Infineon Technologies 2010. All rights reserved.

    IN

    ST

    ESD Logic

    Voltage

    sensor

    Voltage

    source

    Charge pump

    Level shifter

    Rectifier

    Limit forunclampedind. loads

    Gate

    protection

    Currentlimit

    3

    1

    Signal GND

    GND

    2

    VLogic

    Overvoltageprotection

    + Vbb

    PROFET

    OUT

    4

    6, 7

    Load GND

    Load

    GND

    RO

    CurrentSense

    OutputVoltage

    detection

    RIS

    IS5I IS

    IL

    Short circuit

    detection

    Temperature

    sensor

    Block Diagram of a Single-Channel Smart Switch

  • 2010-01-14 Page 16Copyright Infineon Technologies 2010. All rights reserved.

    new 3 seriesold BMW 5 / 7 series

    Body Control Module Evolution Example from BMW

    Smart Power Semiconductors significantly contributed to the Automotive Light Module Evolution

    confidential

  • 2010-01-14 Page 17Copyright Infineon Technologies 2010. All rights reserved.

    Semicon