The Role Of Power Electronics In Reducing Fuel Consumption Feb 2011

COMPANY CONFIDENTIAL 1

The Role of Power Electronics in Reducing Fuel Consumption and Emissions

Andrew Stewart10 February 2011

Advances in Automotive

[email protected]+44 (161) 705-1528+44 (7711) 663820auto.irf.com

COMPANY CONFIDENTIAL

Agenda


Brief introduction to International Rectifier

What is a hybrid?

Biggest Bang for the Buck

Examples of electrification

Handling power

Questions

2


About International Rectifier

NYSE: IRF

• Headquarters: El Segundo, CA

• Fabs: Newport, Wales; Temecula, CA

• Assembly: Tijuana, Mex; Carsem, Malaysia

• Automotive Design Centers: Aix-en-Provence, France; Pavia, Italy; El Segundo, CA

• Semiconductor technologies: MOSFET, HV IC; IGBT; Protected FET

HVAC

Fuel Pump

Oil Pump

Window Lift

Power Seats

Steering

PTC-Heater

Glow Plugs Solenoids

Rear WiperClass D

High End Car HIFI

HID Lighting

Direct Fuel Injection

Braking


IR: A Proud History in Electric Vehicles

1912 Baker Electric Car

•World’s first solar powered automobile

•Panel mounted array of silicon solar cells developed in 1958 by IR

•1270kg with batteries

•10 640 cells – 20kg – 2.4m²

•3HP electric motor

•Maximum speed 30km/h

•Range 80km

4

http://www.youtube.com/watch?v=_CNY0d4EF-s


EV, Fuel Cells… not today

Source: A Short Field Guide to Hybrids, Green Car Congress


New Automotive Innovation & Growth Team Roadmap

6

Source: Department for Business, Innovation & Skills (BIS); UK Governmenthttp://www.bis.gov.uk/policies/business-sectors/automotive/new-automotive-innovation-and-growth-team


Where are we now?

186

162

140

125120

95

70

40

60

80

100

120

140

160

180

200

220

240

1995 2002 2008 2012 2015 2020 2025

CO

2E

mis

sio

ns

(g/

km

)

CO2 Emissions Regulations, Europe 1990 - 2030

• High downsizing• Hybrids (micro & mild)• Gasoline direct injection• Diesel hybrids

• Multi point fuel injection (gasoline)• Common rail injection (diesel)• Diesel engine downsizing

• Engine downsizing (mainly gasoline)• Turbocharging• High pressure common rail• Cylinder deactivation• Gasoline hybrids

• Electrification• Full hybrids

7

Source: Frost & Sullivan


Roadmap to the Zero-Emission Vehicle

Current ICETechnology

Micro Hybrid3 – 10kW

Mild Hybrid15 – 20kW

Full Hybrid200+kW

ElectricVehicle

Fuel CellVehicle

Zero EmissionsVehicle

Time

CO2


Innovation – Fuel Economy & CO2

Source: King Review of Low Carbon Cars and IR Estimates

0 2 4 6 8 10 12

Variable speed fan motor

Reduced friction mechanical components

Electrically Powered Hydraulic Steering

Improved vehicle aerodynamics

Electrically Powered Steering

Downsize engine capacity with turbo charging or supercharging

Direct Injection & lean burn

Hybrid

Variable valve actuation

Stop-Start with regenerative braking

Dual-clutch transmission

Stop-Start

Electric motor assist

% CO2 Reduction / €100

% CO2 Reduction Cost (€)

2 20

4 50

4 50

3 50

5 90

12.5 350

12 450

33 1600

6 300

7 450

7 600

3.5 350

5 1200


Power Steering – when is it needed?

Hydraulic compressors waste power when they are not needed


Electric Replaces Hydraulic

Image courtesy of TRW Automotive

0.15 - 0.3 l/100km saving

1.5 – 5% less CO2

Power Inverter

Gate

drives

M

Control

circuits

(PWM etc.)

AC

in

Input

filterbridge

Bus

Cap

S

Current

sensors

Shaft

sensors

ia,b,c

VBAT+

VBAT-


110W

Traditional system

R

+

-

2 Speeds

Stress

Noisy

€3

80% Cars

The new system

+

-

PWM

10W Variable

Smooth

Quiet

€6

Green cars

Variable Speed Fan Motor

100W electrical = 218 litres fuel saved by using PWM Fan control (*)

Or 0.15L/100km > 3.40g/km C02


Stop-Start Traffic?

Micro Hybrid Stop/Start

• Reinforced starter motor

• Saves 4 – 6% fuel/CO2

Micro/Mild Hybrid Stop/Start

• Belt-driven alternator-starter


Mild Hybrid Stop/Start

• Adds regenerative braking

• Possible booster motor



Stop Start: Integrated Starter-Generator

14

Image courtesy of CPT/GreenCarCongress.com


HVAC Compressor

Image © Delphi

Power Inverter

Gate

drives

M

Control

circuits

(PWM etc.)

AC

in

Input

filterbridge

Bus

Cap

S

Current

sensors

Shaft

sensors

ia,b,c

VBAT+

VBAT-


Direct Injection

Image © Robert Bosch GmbH

Intake Compression Explosion Exhaust

Pmax

Patmo

Pressure Pressure

V0

Patmo

V+V0

Pmax

Volume

Intake Valves

Exhaust Valves

Intake Compression Explosion Exhaust

Pmax

Patmo

Pressure Pressure

V0

Patmo

V+V0

Pmax

Volume

Intake Valves

Exhaust Valves

0 °

18

0 °

36

0 °

54

0 °

72

0 °

Cylinder 1

Cylinder 2

Cylinder 3

Cylinder 4

200 uS

NOTE: Injectors 1&4 will be controlled together by one full-bridge driver (GD1), while injectors 2&3 will be

controlled by a second driver (GD2); therefore, the recharging of the boost capacitor must complement the

firing of the injectors sharing the same H-bridge. Two companion IC's are necessary to control the two gate

drivers used to actuate the 4 injectors. Signal TRIG1 from either companion IC will initiate the actuation of

the first half of the H-bridge (Bank 1), while TRIG2 initiates the second half (Bank 2).

TDCPilot AfterPre Post



TDCPilot

After Post TDCPilotPre

TRIG1 (GD1, Bank

1)

TRIG2 (GD1, Bank

2)

TRIG1 (GD2, Bank

1)

TRIG2 (GD2, Bank

2)

M1

M2

Inj1 Inj4

M1

M2

Bank 1 Bank 2

M1

M2

Inj2 Inj3

M1

M2

Bank 1 Bank 2

Gate Driver 1 (GD1) Gate Driver 2 (GD2)


RD

S(O

N),

Pow

er D

issi

pat

edPower – Choosing the Right Package


APC3 Assembly Concept

• Component can be pick-and-placed onto printed solder paste on the system board or substrate in the same way a smaller component would be.

• Will enable customers to use SMT processes to integrate fully yielded, large area IGBT and diode dies without having to complete subsequent wirebondingprocesses (reducing cost and improving reliability).

• Emitter-up and collector-up to allow easy ½ bridge layouts.

DBC carrier

Customer’s substrate


Thank You


Brief introduction to International Rectifier

What is a hybrid?

Biggest Bang for the Buck

Examples of electrification

Handling power

Questions

19



Contact me:

Office: +44 (161) 705-1528

Cell: +44 (7711) 663820

Web: auto.irf.com

Email: [email protected]

uk.linkedin.com/in/adlstewart

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The Role Of Power Electronics In Reducing Fuel Consumption Feb 2011

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