Browse Topic: Power electronics

Items (179)

A Novel Approach to Make an Efficient Thermal Management of a Solar Electric Four-Wheeler Through Model-Based System Simulation

2024-26-013001/16/2024

The objective of this paper is to determine and design an optimized thermal management system for a solar electric four-wheeler while considering system influence. The major systems that will be analyzed and optimized include the HVAC, solar system, and battery. The HVAC system imposes a challenge to the designers to fulfill the passenger's comfort and to operate it efficiently under a wide range of external loads from solar radiation, ambient temperature & humidity, human metabolic activity, and also other loads like the propulsion system temperature on the cabin. From the literature, it is found that the air conditioning system reduces on average 14% of the total battery capacity whereas the heating system reduces it by 18%, which makes the HVAC system design a crucial aspect to consider for the system influence. The battery car voltage changes significantly to meet the power demand and because of this, the battery system produces a large amount of heat while discharging which will

Karthikeyan, Vikram Raj, Gumma, Muralidhar

Systems Engineering – a key approach to Transportation Electrification

2024-26-012801/16/2024

The automotive industry has seen accelerating demand for electrified transportation. While the complexity of conventional ICE vehicles has increased, the powertrain still largely consists of a mechanical system. In contrast, vehicle architectures in electrified transportation are a complex integration of power electronics, batteries, control units, and software. This shift in system architecture impacts the entire organization during new product development, with increased focus on high power electronic components, energy management strategies, and complex algorithm development. Additionally, product development impact extends beyond the vehicle and impacts charging networks, electrical infrastructure, and communication protocols. The complex interaction between systems has a significant impact on vehicle safety, development timeline, scope, and cost. A systems engineering approach, with emphasis on requirements definition and traceability, helps ensure decomposition of top level

Narasipuram, Rajanand Patnaik, Karkhanis, Varad Abhimanyu, Ellinger, Michael, K M, Saranath, Alagarsamy, Guruprasath, Jadhav, Ravindra

Measurement uncertainty and its influence on e-Drive optimization applications

2024-26-009701/16/2024

This paper gives insights in the theoretical measurement uncertainty of E-Drive rotor position dependent results, like Id and Iq calculations, done by a modern propulsion power analyzer (PA). The calculation of Id and Iq is fundamental to perform control optimization and application tasks for an E-Drive system. In order to optimize the E-Drive system application towards e.g. best efficiency, best performance, or improved NVH the importance of the testing toolchain is described: a power analyzer delivering the required results, an automation system, and a Design of Experiment tool to set improved target values. Consequently, inverters applications featuring field-oriented control (FOC) with permanent magnet synchronous machines (PMSM) are updated with a chosen control strategy. For achieving a certain behavior of an E-Drive, different degrees of freedom in the Inverter Control Unit are available; Lookup tables Id and Iq represent two fundamental application labels to be considered

Platzer, Thomas, Fechter, Michael, Kammerstetter, Heribert, Kolb, Philipp

A review on Electric Vehicle NVH challenges and recent trends

2025-01-004205/05/2023

Electric vehicles (EVs) present a distinct set of challenges in noise, vibration, and harshness (NVH) compared to traditional internal combustion engine (ICE) vehicles. As EVs operate with significantly reduced engine noise, other sources of noise, such as motor whine, power electronics, and road and wind noise, become more noticeable. This review paper explores the key NVH issues faced by EVs, including high-frequency tonal noise from electric motors, gear meshing, and vibrations. Additionally, it examines recent advancements and trends in NVH mitigation techniques, such as active noise control, improved material insulation, and advanced vibration isolation systems. Furthermore, this paper discusses the role of computational tools, simulation technologies, and testing methodologies in predicting and addressing NVH concerns in EVs. By providing an in-depth analysis of the challenges and the latest innovations, this review aims to contribute to the ongoing development of quieter and

Hazra, Sandip, Khan, Arkadip Amitava

A Comprehensive Evaluation of PU Foam for EV NVH Performance

2025-01-012005/05/2023

Low density polyurethane foam was first proposed as an alternative to expandable baffles and tapes for sealing vehicle body cavities towards the end of the last century. In spite of several inherent advantages for cavity sealing, the high equipment cost of dispensing amongst other reasons, this technology has not spread as widely as expected. With the advent of electric vehicles, there is an increased emphasis on controlling higher frequencies from motors, inverters and other components, and polyurethane foam can be a viable solution by providing more robust sealing. Polyurethane foam sealing is already being employed in the new breed of electric vehicles but its NVH advantages have not been fully studied or published in literature. Using an existing electric vehicle with conventional expandable baffles & tape sealing measures, a comprehensive evaluation of NVH performance using the closed-cell polyurethane foam solution was carried out. Testing included component level bench test on

Kavarana, Farokh, Guertin, Bill, Braun, Arnold, Hand, Joshua, Thota, Manoj

Methodology for Radiated Noise Refinement of Electrified Drivetrain Systems

2025-01-009805/05/2023

Electric drive units (EDU) of battery electric vehicles and electric drivetrain components of hybrid vehicles require significant development effort and planning to ensure that a refined NVH sound quality is achieved. New tools and methods are required to understand the NVH performance throughout the development process and to ensure that NVH risks can be quickly identified and mitigated within the correct EDU subsystems. This paper discusses the development of a methodology (EDSL – Electric Drive Sound Level) aimed at addressing this need. It also outlines how the EDSL tool can be used to address radiated noise issues and understand the NVH performance of the various subsystems within an electrified drivetrain component. The first use of the EDSL methodology is to characterize component-level radiated noise test results and compare the different mechanical and electrical noise sources to targets. The results from this are used to guide EDU development in the appropriate areas

Pruetz, Jeffrey E., Steffens, Christoph, Fu, Tongfang, Govindswamy, Kiran

Immersion Cooling for Power Electronics

2022-28-044611/09/2022

The ability to precisely control electrical voltages on a large scale has made possible many efficient, powerful innovations, from high-speed electric trains to wind turbines to electric drive motors for everything from heavy earthmoving equipment to personal electric vehicles (EVs). But the equipment that manages this process — including power inverters, thyristors and variable-speed drives — requires high-performance power electronics cooling. As temperatures rise, the efficiency, reliability, and life spans of these devices drop, and the power electronics inside HEVs and EVs are no exception. Advancements in power electronic thermal management technologies will enable next generation automotive to fulfill increasingly demanding mission objectives. DC-DC converter and inverter systems slated for higher performances, reliable and sustainable applications. Even with very high efficiencies, the components of these systems produce kilowatts of power loss in the form of heat. The current

Using Miniaturized Power Modules to Reduce the Weight and Volume of the Power Electronics

2022-01-088103/29/2022

New EV’s consume up to 20x more electric power (going from 3kW to over 50kW) which puts significant strain on the power delivery network. Hard switching DC-DC converter topologies result in a hefty increase in conventional power electronics that consume space, increase weight and limit range. Using miniaturized, thermally adept power modules, the power electronics can be reduced significantly and save up to 50% in size and 80% in weight. To meet the immediate and long-term demands of EV power requires innovation and miniaturization of solutions that are flexible, scalable, and re-usable. The ability to convert power between 800/400V and 48 /12 V at high efficiency leveraging fast transients can revolutionize automotive power electronics. A modular approach using fixed ratio converters further reduces size and weight throughout the vehicle by reducing cabling and harness weight. Scalable modules can be added and substituted to create flexible designs that reduce part qualification time

Green, Gregory, Kowalyk, Patrick

Multi-objective Finite Control Set Model Predictive Control for Interior Permanent Magnet Motors in Electric/Hybrid-Electric Vehicle Applications

2022-01-041703/29/2022

The rapid growth of electric and hybrid-electric vehicles (EV/HEV) in the automotive industry has created a need for state-of-the-art technologies to improve their performance, reliability, and cost. EV/HEV powertrains include one or more electric motors to deliver power to the wheels and are essential components in the system. Therefore, it is imperative to develop suitable drive control methodologies that produce the required torque/speed demands and ensure safe and efficient operation under challenging circumstances. Two of the biggest concerns in electric motors and their inverter feeder are thermal cycling and overheating, which lead to component degradation and failures that increase maintenance frequency and reduce the vehicle’s overall lifespan. This study augments the finite control set model predictive control (FCS-MPC) into a multi-objective methodology that includes electric power quality, inverter thermal cycling, and motor thermal efficiency. Suitable lumped-parameter

Badr, Payam R., Ozkan, Gokhan, Hoang, Phuong, Edrington, Christopher S., Parker, Tanner

Eliminating the 12V battery with use of Sine Amplitude Converter modules to create 12V power from the high voltage vehicle battery

2022-01-082303/29/2022

The 12V lead-acid car battery is dead. Europe has decreed that no new cars will have lead-acid batteries after 2030, creating a considerable challenge for OEMs to find alternative solutions. Power modules leveraging Sine Amplitude Converter (SAC™) topology enable replacement of the 12V battery by directly converting power from the high voltage (400V or 800V) main vehicle battery. The primary battery (800v/400v) can directly power 12V loads only with high density DC-DC converter with a transient response that meets or exceeds the performance of a 12V battery. Power modules leveraging proprietary SAC topology far exceeds the slew rate—the transient response—of 12V lead-acid batteries in a much smaller and lighter system. A modular approach leveraging SAC can process millions of amperes per second from the high voltage battery to the load eliminating any dips or loads falling out of regulation. Bench testing shows that modular power can deliver a response three times faster than a typical

Kowalyk, Patrick

Case Study on Optimized Cooling System Concept for Electric Compact-SUV with Indian Environmental Conditions

2021-26-041009/22/2021

With the rising emission level in Indian cities, the focus on pure battery electric vehicle is increasing also in India. The Government of India his also focusing on preparing right policies like FAME-2 to promote the acceptability of EV's by providing subsidies as well as creating the required infrastructure. The environmental conditions in India is much different than other developed countries of Euro, China etc. The max. temperatures in India can go up to 55℃ in the hottest summer time, while during winters temperature can go up to <-25℃ in the northern Himalia region. In these conditions the cooling system of the electric-powertrain components like E-Machine Battery pack etc have to be protected for worst case scenarios specific to Indian conditions. Major cost driver of EV's lie in the HV battery packs and it is very important for acceptability of EV's that the Battery is maximized. With fast discharging and charging phenomena of battery pack required in automotive application can

Emran, M.Sc. Ashraf, Garg, Shivam, Manns, M.Sc. Patrick, Sharma, Vijay

How 3D printing could add efficiency to EV power electronics

21AUTP05_0805/01/2021

“Think production!” Perhaps that advice should be posted on the wall of every design office, R&D lab and advanced technology center in the auto industry. Although obeying that warning is clearly not cost-effective in some instances, others are ostensibly perfect to take their place in volume manufacture. An example is 3D printing (aka additive manufacturing, or AM), but despite a broadening scope that now embraces rapid prototyping and tooling by entire houses, it could do better in series production of auto components, particularly in the new world of EVs. Prof. Peter Wilson of the U.K.'s newly established Institute for Advanced Automotive Propulsion Systems (IAAPS) at the University of Bath, noted the growing adoption of high-speed SiC (silicon carbide) and other wide-band-gap semiconductor devices demonstrates the benefits that 3D printing could have in the production of EV inverters. “SiC devices offer so much opportunity to improve inverter performance,” Wilson said. “But system

Empowering Soldiers Through ISPDS

21AERP02_0102/01/2021

According to research conducted by MarketsandMarkets (Northbrook, IL), the military wearables market is projected to grow from $4.2 billion in 2019 to $6.4 billion by 2025. That's a 7.2% growth from 2019 in six short years. Soldier modernization programs that increase soldier coordination, rising asymmetric warfare, and potential geopolitical conflicts are all factors fueling the growth of this market. As soldier-carry technologies continue to expand in scope, soldier power solutions are becoming a critical operational issue. Without access to adequate power, however, these technologies (that include mobile control, communications, intelligence, reconnaissance, surveillance, etc.) become useless on the battlefield and rapidly degrade capabilities. When without sufficient power, the wearable technologies meant to help soldiers more effectively execute operations can instead put them in harms' way.

Tula DMD aims for more-efficient e-machines

20AUTP11_0711/01/2020

The race is on among OEMs and suppliers to optimize the efficiency, performance and cost of electric-vehicle (EV) propulsion systems. Electric machines have moved to the front of the development class, with engineers working to squeeze gains out of devices that are already, in some cases, more than 90% efficient. Tula Technologies is well known within the IC engine community for its Dynamic Skip Fire (DSF) control technology that enables rapid, precise “any time, any cylinder” cylinder deactivation (see SAE Tech Paper 2013-01-03599) for improved fuel economy and reduced NVH. The company's latest innovation, Dynamic Motor Drive (DMD), uses control fundamentals proven in production DSF applications and extends them into e-machines.

Brooke, Lindsay

Soft Magnetic Nanocomposite for High-Temperature Applications

TBMG-3798011/01/2020

Commercial soft magnetic cores used in power electronics are limited by core loss and decreased ferromagnetism at high temperatures. Extending functional performance to high temperatures enables increased power density in electric systems with fixed power output and elevated operating temperature.

Possible Significant Response Speedup from Detuning a Resonator Bolometer

TBMG-3778810/01/2020

Kinetic inductance bolometers and calorimeters, each consisting of a kinetic inductance device (KID) suspended on a membrane and embedded in a resonant circuit, are being developed for applications such as planetary science, climate science, and X-ray spectroscopy. Arrays of these resonator-bolometers, each with a unique resonant frequency, are coupled to a single feedline, allowing many bolometers or calorimeters to be multiplexed using microwave readout. These devices potentially offer a combination of high sensitivity, large arrays, and broadband response not available from competing technologies.

Products of Tomorrow: September 2020

TBMG-3763009/01/2020

This column presents technologies that have applications in commercial areas, possibly creating the products of tomorrow. To learn more about each technology, see the contact information provided for that innovation.

Development of RC-IGBT with a New Structure That Contributes to Both Reduced Size of Power Control Unit and Low Loss in Hybrid Electric Vehicles

2020-01-059604/14/2020

In order to improve the fuel efficiency of Hybrid Electric Vehicles (HEVs), it is necessary to reduce the size and power loss of the HEV Power Control Units (PCUs). The loss of power devices (IGBTs and FWDs) used in a PCU accounts for approximately 20% of electric power loss of an HEV. Therefore, it is important to reduce the power loss while size reduction of the power devices. In order to achieve the newly developed PCU target for compact-size vehicles, the development targets for the power device were to achieve low power loss equivalent to its previous generation while size reduction by 25%. The size reduction was achieved by developing a new RC-IGBT (Reverse Conducting IGBT) with an IGBT and a FWD integration. As for the power loss aggravation, which was a major issue due to this integration, we optimized some important parameters like the IGBT and FWD surface layout and backside FWD pattern. As a result, it was possible to avoid the snapback characteristic (IGBT loss aggravation

Murakami, Koichi, Rahman, Tasbir, Kimura, Keisuke, Konishi, Masaki, Iguchi, Hiroko, Kawaji, Sachiko

Development of New Power Control Unit with Small Size and Low Cost for Small Hybrid Vehicle with Two-motor Hybrid System

2020-01-045804/14/2020

A new power control unit (PCU) has been developed for a Honda small hybrid vehicle with a two-motor hybrid system launched in 2020. For small hybrid vehicles, downsizing and reducing costs of hybrid systems are major challenges. As such, there were emphatic requirements for the newly developed PCU to be small and affordable. To satisfy these requirements for the PCU, new technologies and components have been introduced such as an all-in-one type intelligent power module (IPM) with integrated functions and reverse conducting IGBT (RC-IGBT), a new control sequence for voltage control unit (VCU), and revised PCU packaging to improve cooling performance. The new IPM has a printed-circuit board (PCB) equipped with an electric control unit (ECU) and gate drive circuits, 7 current sensors, and a power module with RC-IGBTs. This functional integration led to a reduction in the number of main electrical PCU assembly components from 9 in the previous PCU to 2 in the new PCU. In addition, the

Nonaka, Kenichi, Takebayashi, Kenichi, Kashimura, Yukiya, Ueno, Yuichiro, Kondo, Yasuhiko

Current control method for asymmetric dual three-phase Permanent Magnet Synchronous Motor

2020-01-047004/14/2020

Based on the vector space decomposition (VSD) transformation, the phase currents of the asymmetric dual three phase permanent magnet synchronous motor (ADT-PMSM) can be mapped into three orthogonal subspaces, i.e., α–β subspace, x-y subspace and O1-O2 subspace. The mechanical energy conversion takes place in the α–β subspace, while in the x-y and O1-O2 subspaces only losses are produced. With neutral points being isolated, O1-O2 subspace can be omitted. So the vector control algorithm can control the α–β and x-y subspaces separately to realize the four dimensional current control. In the α–β subspace, deviation decoupling control method is employed to realize the mechanical energy conversion, which is robust to the motor parameters. In order to reduce the 5th and 7th harmonic currents caused by the inverter nonlinearity and some other factors, a resonant controller is adopted based on a new synchronous rotating coordinate transformation matrix to implement the current closed loop

Wu, Zhihong, Gu, Weisong, Zhu, Yuan, Lu, Ke

EDITORIAL: EVs and the retail-price reset

20AUTP04_0504/01/2020

Before the coronavirus uprooted and replanted our collective focus, American politics dominated the news cycle. One night on TV I heard a presidential candidate talking about the need for “affordable” vehicles. They had to be electric, of course, and offer all the comfort, convenience and safety features the buying public expects and that regulators demand is a good place to start, the forward-thinking politico suggested. And cost? Around…$18,000. Eighteen grand for a new car! Dream on. The average transaction price for a light vehicle in the U.S. today is nearing $40,000. Creating any new vehicle that can slash sticker prices by 54% would be a monumental feat, requiring a total reboot of vehicle design, engineering, manufacturing and sales. For the past 35 years I've listened to company leaders, engineers and researchers promise “game changers” and and “right-around-the-corner” technologies. At automotive scale, these would enable cheaper autos. Potentially. If only.

Brooke, Lindsay

Electric Vehicle Power Transfer System Using Conductive Automated Connection Devices Vehicle-Mounted Pantograph (Bus-Up)

J3105/2_202001 (Current)01/20/2020

This document details one of the connections of the SAE J3105 document. The connections are referenced in the scope of the main document SAE J3105. SAE J3105/2 details the vehicle-mounted pantograph, or the bus-up connection. All the common requirements are defined in the main document; the current document provides the details of the connection. This document covers the connection interface relevant requirements for an electric vehicle power transfer system using a conductive automated charging device based on a conventional rail vehicle pantograph design. To allow interoperability for on-road vehicles (in particular, buses and coaches), one configuration is described in this document. Other configurations may be used for non-standard applications (for example, mining trucks or port vehicles).

Hybrid - EV Committee

Electric Vehicle Power Transfer System Using Conductive Automated Connection Devices Enclosed Pin and Socket Connection

J3105/3_202001 (Current)01/20/2020

This document details one of the connections of the SAE J3105 document. The connections are referenced in the scope of the main document SAE J3105. SAE J3105/3 details the enclosed pin and sleeve connection. All the common requirements are defined in the main document; the current document provides the details of the connection. This document covers the main safety and interoperability relevant requirements for an electric vehicle power transfer system using a conductive automated charging device based on an enclosed pin and socket design. To allow interoperability for on-road vehicles (in particular, buses and coaches), one configuration is described in this document. Other configurations may be used for non-standard applications (for example, mining trucks or port vehicles).

Hybrid - EV Committee

Design and Analysis of Sigma Z-Source Inverter for PV Applications

2019-28-012310/11/2019

Traditional Voltage Source Inverter (VSI) produces lesser output voltage than the input and causes shoot-through due to the gating of the semiconductor device connected in same leg. The ZSI is used to overcome the inadequacies of VSI. The ZSI has been extensively used in electric drives, PV system and UPS. The conventional ZSI suffers some disadvantages like restricted boost capability, discontinuity in input current and large inrush current. These limitations are overcome by using a transformer which replaces the inductor in the impedance source network. In high-voltage gain applications, the single transformer-based ZSI topologies requires more turns ratio which requires large size transformer. For improving the boost capability, the TZSI is used. The Z-source network of the TZSI constitutes two transformers with low turns ratio. TZSI has certain demerits such as restricted boost capability, high inrush current and discontinuity in the input current. However, TZSI requires high turns

Nallathambi, Kalaiarasi, Rangarajan, Uthra, Daniel, Anitha

General Requirements for Powered Drive Units (PDUs) in Aircraft Cargo Systems

AIR4165B (Current)10/02/2019

This SAE Aerospace Information Report (AIR) is intended to assist the user (aircraft manufacturer/airline) in the following areas: a In the decision of whether or not to plan for the installation of a powered drive system in the cargo loading system (CLS) during the definition of the aircraft on-board cargo loading system. b If a powered drive system is decided upon, to provide general requirements to be considered during the preparation of component specifications for the powered drive units (PDUs) to be used. This provides a selection of criteria in order to obtain an optimum PDU for the application considered.

AGE-2 Air Cargo

SAE Eye on Engineering: Here Come 800-Volt Inverters

1245809/24/2019

In electric vehicle technology, the inverter is the unsung hero. In this episode of SAE Eye on Engineering, Editor-in-Chief Lindsay Brooke looks at Delphi's new 800-volt inverter. SAE Eye on Engineering also airs Monday mornings on WJR 760 AM Detroit's Paul W. Smith Show.

Engineering, Automotive

ZF shifts EV transmission efficiency up a gear

19AUTP09_1209/01/2019

ZF Project Engineer Volker Vogel checked that the Lausitzring test track ahead was clear and announced: “Now from stationary on full throttle.” From the rear of the prototype van came the almost instant and familiar whine of a very busy electric motor as the speed built. Then, the unexpected: A slight change in volume at 70 kph (44 mph) as the transmission shifted to a second gear. “It is only at prototype stage.” Implicit in Vogel's words was the need to make allowances. But that was not necessary; as shifters go, this is a real smoothie.

Module or Discrete Power?

TBMG-3491108/01/2019

Engineers today are feeling the pressure to get more done in less time, be experts in multiple disciplines, and use their resources more efficiently to maximize profits. This environment is shifting the way engineers approach finding solutions to their most pressing challenges, especially when it comes to the unavoidable necessity of power provision.

Medium-Frequency Transformer Transitions from AC to DC

TBMG-3441005/01/2019

Traditionally, electronics are cooled using a heat sink that transfers the heat generated by the electronic system into the air or a liquid coolant. For the heat sink to work, it has to be attached to the CPU or the graphics processor via a thermal interface material such as thermal paste. It helps facilitate the transfer of heat by bridging microscopic gaps between the heat sink and the chip.

Development of TLP-AI Technology to Realize High Temperature Operation of Power Module

2019-01-060704/02/2019

Application of SiC power devices is regarded as a promising means of reducing the power loss of power modules mounted in power control units. Due to those high thermostable characteristics, the power module with SiC power devices are required to have higher operating temperature than the conventional power module with Si power devices. However, the limitations of current packaging technology prevent the utilization of the full potential of SiC power devices. To resolve these issues, the development of device bonding technology is very important. Although transient liquid phase (TLP) bonding is a promising technology for enabling high temperature operation because its bonding layer has a high melting point, the characteristics of the TLP bonding layer tend to damage the power devices. This paper describes the development of a bonding technology to achieve high temperature operation using a stress reduction effect. Called transient liquid phase bonding with an aluminum interlayer (TLP-AI

Asai, Rintaro, Ito, Hirofumi, Usui, Masanori, Aoshima, Masaki

19AUTP02_1802/01/2019

Which premium vehicle OEM currently offers the broadest range of plug-in vehicles? That would be BMW, with 12 production hybrids and battery EVs including new-for-2019 PHEV variants of the 3-Series sedan and X5. With many more in the pipeline and the company's fifth-generation electric drive system in development for 2020, Automotive Engineering Editor Lindsay Brooke sat down recently with Stefan Jurascheck, BMW VP Development for Electric Powertrains, to discuss details of “the ultimate electrified driving machine.” Jurascheck, an electrical engineer, is a 32-year BMW veteran. BMW's next-gen electric drive architecture is due to launch in 2020. What can you tell us?

Thinking Ahead Thermally: A Guide to Thermal Management Considerations for Medical Devices, Part 2

TBMG-3357101/01/2019

As the medical device and engineering industry grows, there is also demand for better devices and equipment. Trends such as smaller and more powerful electronics, as well as increased focus on improved customer experience, affect the medical device industry as much as any other. Medical devices, though, also need to be portable, and their costs must be judiciously managed. Above all, reliability is crucial.

19AUTP08_2101/01/2019

Sean Stanley is one of a new generation of motorcycle engineers who are as fluent in battery cooling and electronics integration as their predecessors were in optimizing cam profiles and compression ratios. As Harley-Davidson's EV Systems chief engineer, Stanley, along with EV Platform chief Glen Koval and their teams, have brought the 2020 LiveWire e-bike from a bold concept in 2011 to production, which is getting underway at H-D's York, Pennsylvania, assembly plant. LiveWire is nothing like your granddad's Shovelhead, aside from the brand name on the faux ‘gas tank.’ There are five ECUs on board controlling seven rider-selectable and customizable ride modes. Rear-wheel lift mitigation is managed by a 6-axis inertial measurement unit (IMU). The 15.5-kWh Samsung SDI lithium-ion battery, liquid cooled 78-kW (108-hp) Magneti-Marelli permanent-magnet motor, 1400-watt SAE J1772 ‘Combo’ charging setup, 4.3-in. (109-mm) color thin-film display, and hollow-cast aluminum ‘exoskeleton’ chassis

FCA'S MICKY BLY amping up electrification

19AUTP08_0201/01/2019

New powertrain boss Micky Bly and his team are building an advanced propulsion-strategy roadmap that includes at least one more ICE development cycle. With its asphalt-ripping Hellcat and Demon V8s dominating the engine headlines at FCA North America, and boom times for Ram and Jeep sales, hybridization and battery electric vehicles (EVs) have “not been the leading-edge story,” notes Michael “Micky” Bly, the company's newly arrived head of Powertrain Engine Engineering. And, he acknowledged, the company is clearly perceived as trailing the industry in the new-propulsion space. “When I started the interview process to come to this position, that was one of my questions: ‘Where is FCA? Give me some insight,’” he told Automotive Engineering at the company's recent 2020 product preview. “Because what I'm intrigued about is seeing this technology develop-as well as ICE's continuing progress at the same time.”

BorgWarner demos next-step electrification components

19AUTP01_1101/01/2019

Anyone questioning whether a substantial portion of the light-vehicle market will imminently feature some form of powertrain electrification need look no further than the product portfolios of the major powertrain suppliers. At a recent event at its Propulsion Technical Center in Auburn Hills, Michigan, BorgWarner provided access to a range of demonstration vehicles-from full EVs to hybrid Ford F-150s-featuring technology engineered for OEM's seeking swift electrified integration.

Visnic, Bill, Seredynski, Paul

Gated Chopper Integrator (GCI)

TBMG-3339212/01/2018

Microvolt-level signals require gains of at least a thousand. Offsets and noise in the amplifier chain will be amplified by the same amount, which can saturate the amplifier or swamp the signal so it is not resolvable. Other methods use chopping and/or autozero techniques to lower the offset and noise. The key disadvantages of these methods are they require filters before and/or after demodulation of the amplified signal and delay equalization to account for the delay through the amplifier(s) prior to the demodulator. The gain of these circuits is generally limited to fixed values determined by resistors. These methods are also susceptible to transient noise associated with the switching action of the modulator.

Ultra-Wide-Bandgap Power Electronics

TBMG-2904206/01/2018

Power electronics used for routing, control, and conversion of electrical power traditionally utilize silicon semiconductors. These systems tend to be bulky, require active cooling, and are inadequate for applications demanding portable power conversion requirements (e.g., distributed power generation, vehicles, and satellites).

Transmission-Mounted Power Control Unit Including 12-Volt DC-DC Converter for Two-Motor Hybrid System

2018-01-045704/03/2018

This research proposes a third-generation power control unit (PCU) for a two-motor hybrid system. To make a more compact intelligent power unit (IPU) to be located under the second seat, a PCU with a 12-volt DC-DC converter (DCDC) that mounts directly on the transmission was developed, whereas the DCDC was previously mounted within the IPU. Since this has a considerable impact on the engine room layout, the technology described below was used to make the PCU even more compact than the second-generation unit. The power module, a key component of the PCU, now uses Ag nanoparticles sintering bonding rather than conventional solder bonding. This helps lower thermal resistance and enables smaller power semiconductors. The voltage control unit (VCU) has a new circuit that uses a multi-stage switching circuit and electric power transfer capacitor instead of the conventional chopper circuit. This makes it possible to shrink the reactor to less than 65% of its usual volume without raising the

Ozuchi, Yasuhiro, Tomokage, Ryoji

IGBT Power Modules Evaluation for GM Electrified Vehicles

2018-01-046004/03/2018

GM has recently developed two types of plug-in electric vehicles. First is an extended range electric vehicle such as the Volt, and the second is a battery electric vehicle such as the Bolt. An overview, of traction inverter and power module used in GM battery electric vehicles, is presented. IGBT power modules are critical components used in traction inverters for driving GM Electrified Vehicles. IGBT power modules are also described in a benchmarking study using key metrics based on horizontal die configuration, layout and vertical thermal stack. Power Module evaluation test set up, procedure and instrumentation used in GM Power Module Lab, Pontiac, Michigan are described. GM Electrification development journey depends on IGBT power module passive test benches; turn on/off energy loss tester, thermal resistance tester, and slow/fast power cycles testers (fast junction temperature change, in seconds, and slow baseplate temperature change, in minutes). IGBT power module development

Czubay, John, Chung, Sung, Desai, Prakash H.

A Packaging Layout to Mitigate Crosstalk for SiC Devices

2018-01-046204/03/2018

SiC devices have inherent fast switching capabilities due to their superior material properties, and are considered potential candidates to replace Si devices for traction inverters in electrified vehicles in future. However, due to the comparatively low gate threshold voltage, SiC devices may encounter oscillatory false triggering especially during fast switching. This paper analyzed the causes of false triggering, and also studied the impact of a critical parasitic parameter - common source inductance. It is shown that crosstalk is the main cause for the false triggering in the case and some positive common source inductance help to mitigate the crosstalk issue. A packaging layout method is proposed to create the positive common source inductance through layout of control terminals / busbars, and/or the use of control terminal bonded wires at different height.

Xu, Zhuxian, Chen, Chingchi, Lei, Thomas

Lightweight Carbon Composite Chassis for Engine Start Lithium Batteries

03/07/2018

The supersession of metallic alloys with lightweight, high-strength composites is popular in the aircraft industry. However, aviation electronic enclosures for large format batteries and high power conversion electronics are still primarily made of aluminum alloys. These aluminum enclosures have attractive properties regrading structural integrity for the heavy internal parts, electromagnetic interference (EMI) suppression, electrical bonding for the internal cells, and/or electronics and failure containment. This paper details a lightweight carbon fiber composite chassis developed at Meggitt Sensing Systems (MSS) Securaplane, with a copper metallic mesh co-cured onto the internal surfaces resulting in a 50% reduction in weight when compared to its aluminum counterpart. In addition to significant weight reduction, it provides equal or improved performance with respect to EMI, structural and flammability performance. This application of the technology outlined in this paper pertains to

Mahoney, Brandon, Marshall, Jamie, Black, Thomas, Moxley, Dennis

Integrated Three-Dimensional Module Heat Exchanger for Power Electronics Cooling

TBMG-2780311/01/2017

Critical elements in the operation of electric drive systems are power electronics and power semiconductor packages. Improving thermal management of power electronics can help reduce the cost, weight, and volume of electric drive systems, and thus increase market acceptance. The power semiconductor packaging must provide the necessary electrical connections, while at the same time enabling heat removal from the semiconductor devices such as insulated gate bipolar transistors (IGBTs) and diodes.

Electric Flight Technology

WP-000210/25/2017

The environmental impact of hydrocarbon-burning aircraft, both from the perspective of gas emissions and that of noise, is one of the main motivations for the move to electric propulsion. The added benefit from this shift to electric propulsion is that it has resulted in lowering the costs of electrical components such as motors, power electronic (PE) circuits, and batteries that are essential to this technology. This white paper seeks to explore the history, architecture, electrical components, and future trends of electric flight technology.

Power Systems Infrastructure of Hybrid Electric Fuel Cell Competition Go Kart

2017-01-245210/08/2017

This paper documents the electrical infrastructure design of a Hybrid Go Kart competition vehicle which includes a dual Fuel Cell power system, Ultra Capacitors for energy storage, and a dual AC induction motor capable of independent drive. The Kart was built primarily to compete in the 2009 Formula Zero international event. This paper emphasized the vehicle model and control strategy as a result of three (3) graduate student research projects. The vehicle was fabricated and tested but did not participate in the race competition since the race organization folded. The vehicle model was developed in Simulink to determine whether the fuel cell and ultra-capacitor combination will be sufficient for peak transient power requirement of 14 kW. The vehicle’s functional description and performance specifications are documented including the integration of the fuel cell power modules, energy storage system, power converters, and AC motor and motor controllers.

Berry, Kingsley Joel, Traore, Abdrahamane, Krishna, Aravind, Gangadhar, Pavankumar, Taylor, Allan

Cadillac plugs in CT6 for high-value efficiency

17AUTP10_1510/01/2017

The badge on the decklid reads ‘2.0E’, with no giveaway that the 2018 Cadillac CT6 we're driving is a plug-in hybrid. Perhaps a more appropriate nameplate should be CT6 NEV, because this impressively engaging and efficient luxury sedan is mostly aimed at China's burgeoning New Energy Vehicle market. In fact, the plug-in version is assembled only in Shanghai and is exported to the U.S. Initial stateside volumes will be only 1000 units/year. It would not be surprising to find more American customers who see the CT6 plug-in's almost ideal balance of EV range (31 mi in optimal thermal conditions), EV top speed (78 mph); acceleration (0 to 60 mph in 5.2 s); EPA rated efficiency (62 mpg-e); total range (442 mi), top speed (150 mph) and retail price ($75,095) as adding up to a compelling value proposition.

Brooke, Lindsay

Solder Bond Packaging for High-Voltage Pulsed Power Devices

TBMG-2703406/01/2017

The huge demand for switching components exceeding silicon's (Si) current density limitation of 200 A/cm2 has pushed the enhancement of alternative semiconductor materials such as silicon carbide (SiC), gallium nitride, and diamond. The enhanced material properties of SiC, such as high thermal conductivity, large critical field, wide bandgap, large elastic modulus, and high saturation velocity, make it a viable candidate for pulsed power systems. Using SiC would increase both current and power densities, improve dI/dt and dV/dt capabilities, reduce recovery time, and minimize switching losses in various power electronic systems. Furthermore, a significant reduction in the volume and weight of pulsed power systems can be realized by implementing SiC SGTOs, reducing the thermal management requirements of the pulsed power system.

Shielded Gate Trench Technology for Achieving the Best Performing Automotive MOSFETs in Medium Voltage Applications *CSP Meta QA Testing*

2017-01-001203/28/2017

To meet the increasing demand for lower RDS(ON) MOSFETs in medium voltage automotive applications, the shielded gate trench MOSFET architecture is becoming increasingly popular in recent years for its ability to achieve both lower RDS(ON) and faster switching speed. The lower specific drain-to-source resistance (RDS(ON).Area) translates into smaller chip size and consequently cheaper die cost for the end customers. Furthermore, shielded gate trench architecture offers smaller gate-to-drain capacitance by utilizing the shielding effect from the shield-poly, leading to lower G-D charge (QGD), faster switching speed, and increased dv/dt immunity. A comprehensive portfolio of medium voltage shielded gate power MOSFET products in several voltage classes (40V, 60V, 80V, and 100V) in automotive and industrial markets is presented in this paper. The latest generation shielded gate technologies have the industry leading performance with superior efficiency, better Figure-of-Merits (FOMs), and

Hossain, Zia, Deng, Shengling, Sellers, Jim, Loechelt, Gary, Grimaldi, Mo, Wan, Irene, Linehan, Emily, Young, Alexander, Salih, Ali

A Smart Gate Driver with Active Switching Speed Control for Traction Inverters

2017-01-124303/28/2017

The IGBTs are dominantly used in traction inverters for automotive applications. Because the Si-based device technology is being pushed to its theoretical performance limit in such applications during recent years, the gate driver design is playing a more prominent role to further improve the traction inverter loss performance. The conventional gate driver design in traction inverter application needs to consider worst case scenarios which adversely limit the semiconductor devices' switching speed in its most frequent operation regions. Specifically, when selecting the gate resistors, the IGBT peak surge voltage induced by fast di/dt and stray inductance must be limited below the device rated voltage rating under any conditions. The worst cases considered include both highest dc bus voltage and maximum load current. However, the traction inverter operates mainly in low current regions and at bus voltage much lower than the worst case voltage. This paper proposes a low-cost and simple

Zhou, Yan, Chen, Lihua, Yang, Shuitao, Xu, Fan, Alam, Mohammed Khorshed

Development of a New MOS Rectifier for High-Efficiency Alternators

2017-01-124003/28/2017

For the purpose of improving vehicle fuel efficiency, it is necessary to reduce energy loss in the alternator. We have lowered the resistance of the rectifying device and connecting components, and control the rectifying device with an IC to reduce rectification loss. For the package design, we have changed the structure of the part on which the rectifying device is mounted into a high heat dissipation type. The new structure has enabled optimizing the size of the rectifying device, resulting in the reduction of size of the package. In addition, the rectifying device is mounted using a new soldering material and a new process, which has improved the reliability of the connection. Moreover, since the alternator has introduced a new system, the controller IC has a function for preventing malfunction of the rectifying device and a function for detecting abnormalities, in order to ensure safety. These technologies have realized a low-energy loss high-reliability rectifier, which contribute

Matsushita, Koki

Power MOSFET Technologies and Design Considerations for Automotive Electronic Systems *CSP Meta QA Testing*

2017-01-001603/28/2017

For over thirty years, the silicon power MOSFET’s role has expanded from a few key components in electronic engine control to a key component in nearly every automotive electronics system. New and emerging automotive applications such as 48 V micro hybrids and autonomous vehicle operation require improved power MOSFET performance. This paper reviews mature and state of the art power MOSFET technologies, from planar to shield gate trench, with emphasis on applicability to automotive electronic systems. The automotive application environment presents unique challenges for electronic systems and associated components such as potential for direct short to high capacity battery, high voltage battery transients, high ambient temperature, electromagnetic interference (EMI) limitations, and large delta temperature power cycling. Moreover, high reliability performance of semiconductor components is mandatory; sub 1 ppm overall failure rate is now a fundamental requirement. Autonomous vehicle

Zaremba, Don, Linehan, Emily, Ramirez Ramos, Carlos

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