Folie 1 - Infineon
Folie 1 - Infineon
Folie 1 - Infineon
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On Board Charging:<br />
Concept Considerations and<br />
Demonstrator Hardware<br />
INFINEON TECHNOLOGIES<br />
IMM PSD AI<br />
in cooperation with<br />
finepower
Onboard Charger<br />
Basic Concept Considerations<br />
Confidential Copy<br />
optional power ratings at<br />
220V~ supply<br />
3,6 kW single phase : mainstream<br />
11 kW 3 phase : optionally<br />
22 kW 3 phase : rare cases only ?<br />
Most likely no 40kW onboard<br />
solutions due to weight and size<br />
restrictions<br />
Standard AC fuses and<br />
connectors can be used<br />
between car and<br />
grid infrastructure<br />
Infrastructure<br />
Confidential Copy<br />
2010-01-14 Copyright © <strong>Infineon</strong> Technologies 2010. All rights reserved.<br />
Page 2
Onboard Charger - Value proposition from<br />
customer perspective<br />
Size and Weight<br />
Confidential Copy<br />
Universal input, worldwide use<br />
Flexibility to choose one phase / three phase supply<br />
Inherent safety concept<br />
L1<br />
L2<br />
L3<br />
N<br />
Filter Rect<br />
PFC DC/DC<br />
Powernet<br />
Comm<br />
AC/DC<br />
E Earth to Ground<br />
G<br />
Driver Logic<br />
Diagnosis/Monitoring<br />
Authentication/Billing<br />
Car<br />
Comm<br />
Confidential Copy<br />
2010-01-14 Copyright © <strong>Infineon</strong> Technologies 2010. All rights reserved.<br />
Page 3<br />
HV+<br />
HV-
Rectification and active PFC :<br />
basic motivation and features<br />
85-265VAC<br />
power factor >0,9<br />
Legally required<br />
Confidential Copy<br />
constant DC link output voltage, typically 400V<br />
1.5% efficiency loss from bridge rectifier in low line (110V) operation<br />
Continuous and Discontinuous current mode possible<br />
Confidential Copy<br />
2010-01-14 Copyright © <strong>Infineon</strong> Technologies 2010. All rights reserved.<br />
Page 4
Bridgeless Resonant PFC concept,<br />
single stage only<br />
90-240 VAC<br />
Confidential Copy<br />
D3..4 S3..4<br />
D1..2<br />
S1..2<br />
Confidential Copy<br />
400 VDC<br />
2010-01-14 Copyright © <strong>Infineon</strong> Technologies 2010. All rights reserved.<br />
Page 5
Bridgeless Resonant PFC concept,<br />
single stage only<br />
90-240 VAC<br />
switching pattern Confidential during Copy positive AC half wave<br />
D3..4 S3..4<br />
+<br />
-<br />
D1..2<br />
charging<br />
S1..2<br />
Confidential Copy<br />
400 VDC<br />
2010-01-14 Copyright © <strong>Infineon</strong> Technologies 2010. All rights reserved.<br />
Page 6
Bridgeless Resonant PFC concept,<br />
single stage only<br />
90-240 VAC<br />
switching pattern Confidential during Copy positive AC half wave<br />
D3..4 S3..4<br />
+<br />
-<br />
D1..2<br />
boosting<br />
S1..2<br />
Confidential Copy<br />
400 VDC<br />
2010-01-14 Copyright © <strong>Infineon</strong> Technologies 2010. All rights reserved.<br />
Page 7
Bridgeless Resonant PFC concept,<br />
single stage only<br />
90-240 VAC<br />
-<br />
+<br />
switching pattern Confidential during Copy negative AC half wave<br />
D3..4 S3..4<br />
D1..2<br />
charging<br />
S1..2<br />
Confidential Copy<br />
400 VDC<br />
2010-01-14 Copyright © <strong>Infineon</strong> Technologies 2010. All rights reserved.<br />
Page 8
Bridgeless Resonant PFC concept,<br />
single stage only<br />
90-240 VAC<br />
-<br />
+<br />
switching pattern Confidential during Copy negative AC half wave<br />
D3..4 S3..4<br />
D1..2<br />
boosting<br />
S1..2<br />
Confidential Copy<br />
400 VDC<br />
2010-01-14 Copyright © <strong>Infineon</strong> Technologies 2010. All rights reserved.<br />
Page 9
Bridgeless Resonant PFC concept : <strong>Infineon</strong> OBC<br />
solution utilizes two interleaved stages<br />
90-240 VAC<br />
Confidential Copy<br />
D3..4 S3..4<br />
D1..2<br />
Devices Function IFX part<br />
S1..S4 Resonant PFC switches 600V CoolMOS CFD<br />
D1..4 Rectifier diodes --<br />
Confidential Copy<br />
S1..2<br />
400 VDC<br />
2010-01-14 Copyright © <strong>Infineon</strong> Technologies 2010. All rights reserved.<br />
Page 10
Bridgeless Resonant PFC concept : <strong>Infineon</strong> OBC<br />
solution utilizes two interleaved stages<br />
90-240 VAC<br />
D3..4<br />
+<br />
-<br />
D1..2<br />
Confidential Copy<br />
charging<br />
Confidential Copy<br />
S3..4<br />
S1..2<br />
Devices Function IFX part<br />
S1..S4 Resonant PFC switches 600V CoolMOS CFD<br />
D1..4 Rectifier diodes --<br />
400 VDC<br />
2010-01-14 Copyright © <strong>Infineon</strong> Technologies 2010. All rights reserved.<br />
Page 11
Bridgeless Resonant PFC concept : <strong>Infineon</strong> OBC<br />
solution utilizes two interleaved stages<br />
90-240 VAC<br />
Confidential Copy<br />
D3..4 S3..4<br />
+<br />
-<br />
D1..2<br />
boosting<br />
charging<br />
Devices Function IFX part<br />
S1..S4 Resonant PFC switches 600V CoolMOS CFD<br />
D1..4 Rectifier diodes --<br />
Confidential Copy<br />
S1..2<br />
400 VDC<br />
2010-01-14 Copyright © <strong>Infineon</strong> Technologies 2010. All rights reserved.<br />
Page 12
Bridgeless Resonant PFC concept : <strong>Infineon</strong> OBC<br />
solution utilizes two interleaved stages<br />
90-240 VAC<br />
Confidential Copy<br />
D3..4 S3..4<br />
+<br />
-<br />
D1..2<br />
charging<br />
boosting<br />
Devices Function IFX part<br />
S1..S4 Resonant PFC switches 600V CoolMOS CFD<br />
D1..4 Rectifier diodes --<br />
Confidential Copy<br />
S1..2<br />
400 VDC<br />
2010-01-14 Copyright © <strong>Infineon</strong> Technologies 2010. All rights reserved.<br />
Page 13
Bridgeless Resonant PFC concept : <strong>Infineon</strong> OBC<br />
solution utilizes two interleaved stages<br />
Confidential Copy<br />
Confidential Copy<br />
2010-01-14 Copyright © <strong>Infineon</strong> Technologies 2010. All rights reserved.<br />
Page 14
DC/DC (LLC) converter : <strong>Infineon</strong> OBC<br />
solution implements galvanic isolation<br />
400<br />
VDC<br />
S1<br />
S2<br />
S3<br />
S4<br />
Confidential Copy<br />
Devices Function IFX part<br />
S1..S4 Resonant LLC switches 600V CoolMOS CFD<br />
D1..4 Rectifiier diodes 600V fast switching Diode IDP23E60<br />
Confidential Copy<br />
250..400<br />
2010-01-14 Copyright © <strong>Infineon</strong> Technologies 2010. All rights reserved.<br />
Page 15<br />
D1<br />
D2<br />
D3<br />
D4<br />
VDC
<strong>Infineon</strong> OBC solution<br />
System Features (1)<br />
HV Charger:<br />
90 – 240 VAC in<br />
200 – 400 VDC out<br />
16 A(rms), one phase<br />
¬ 3.6kW @230V<br />
Interleaved PFC<br />
LLC converter<br />
PLD controlled<br />
12V Charger:<br />
100 W output<br />
from 400 VDC<br />
intermediate voltage<br />
Confidential Copy<br />
CAR<br />
AC<br />
socket<br />
Proximity Sensors<br />
Confidential Copy<br />
2010-01-14 Copyright © <strong>Infineon</strong> Technologies 2010. All rights reserved.<br />
Page 16<br />
HP or G.HN (2)<br />
L2<br />
L3<br />
OBC<br />
L1<br />
PE<br />
Interleaved PFC<br />
POWER<br />
UNIT L1<br />
Supply<br />
Vpfc, Ipfc<br />
PFC ctr<br />
Temp 1_L1<br />
Temp 1_L2<br />
Temp 1_L3<br />
SPI ph_L2<br />
SPI ph_L3<br />
HP/G.HN<br />
GATEWAY<br />
HVIL-LOGIC<br />
CTR UNIT L1<br />
HVIL<br />
ISOL CAN (opt.)<br />
Vpfc_L1<br />
XC2000<br />
CAN<br />
BMS<br />
CAN BUS<br />
Vout_L2<br />
Vout_L3<br />
PLD<br />
= To phase board L2<br />
= To phase board L3<br />
CAN BUS<br />
HiV BATT<br />
HVIL<br />
LLC converter<br />
LLC ctr<br />
Vout, Iout<br />
Temp 2<br />
Temp 2_L2<br />
Temp 2_L3<br />
Vout<br />
12V<br />
Charger<br />
CTR<br />
Vout_L1<br />
12V<br />
12Vout_L1<br />
12V BATT<br />
Galvanic<br />
Isolation
<strong>Infineon</strong> OBC solution<br />
System Features (2)<br />
In-car communication:<br />
CAN with wake-up<br />
External interface:<br />
Isolated UART over USB<br />
Isolated CAN<br />
HP/G.HN gateway<br />
System monitoring:<br />
Over-temperature<br />
Over-current<br />
Over-under voltage<br />
Auxiliary:<br />
Proximity sensors<br />
HVIL (Interlock)<br />
Confidential Copy<br />
CAR<br />
AC<br />
socket<br />
Proximity Sensors<br />
Confidential Copy<br />
2010-01-14 Copyright © <strong>Infineon</strong> Technologies 2010. All rights reserved.<br />
Page 17<br />
HP or G.HN (2)<br />
L2<br />
L3<br />
OBC<br />
L1<br />
PE<br />
Interleaved PFC<br />
POWER<br />
UNIT L1<br />
Supply<br />
Vpfc, Ipfc<br />
PFC ctr<br />
Temp 1_L1<br />
Temp 1_L2<br />
Temp 1_L3<br />
SPI ph_L2<br />
SPI ph_L3<br />
HP/G.HN<br />
GATEWAY<br />
HVIL-LOGIC<br />
CTR UNIT L1<br />
HVIL<br />
ISOL CAN (opt.)<br />
Vpfc_L1<br />
XC2000<br />
CAN<br />
BMS<br />
CAN BUS<br />
Vout_L2<br />
Vout_L3<br />
PLD<br />
= To phase board L2<br />
= To phase board L3<br />
CAN BUS<br />
HiV BATT<br />
HVIL<br />
LLC converter<br />
LLC ctr<br />
Vout, Iout<br />
Temp 2<br />
Temp 2_L2<br />
Temp 2_L3<br />
Vout<br />
12V<br />
Charger<br />
CTR<br />
Vout_L1<br />
12V<br />
12Vout_L1<br />
12V BATT<br />
Galvanic<br />
Isolation
<strong>Infineon</strong> OBC solution :<br />
Control Partitioning<br />
PLD is responsible for:<br />
Confidential Copy<br />
Low-level high-voltage control (Interleaved PFC & LLC)<br />
Over-voltage, over-current detection<br />
Microcontroller is responsible for:<br />
In-car communication<br />
External communication<br />
12V battery charger control<br />
ECU/board management<br />
ASIL / general system monitoring: Voltage, Current,<br />
Temperature.<br />
Confidential Copy<br />
2010-01-14 Copyright © <strong>Infineon</strong> Technologies 2010. All rights reserved.<br />
Page 18
<strong>Infineon</strong> OBC solution :<br />
system partitioning<br />
Confidential Copy<br />
Confidential Copy<br />
2010-01-14 Copyright © <strong>Infineon</strong> Technologies 2010. All rights reserved.<br />
Page 19
Schematic Diagram of PFC<br />
Confidential Copy<br />
Confidential Copy<br />
2010-01-14 Copyright © <strong>Infineon</strong> Technologies 2010. All rights reserved.<br />
Page 20
PFC, functional details<br />
Confidential Copy<br />
Confidential Copy<br />
2010-01-14 Copyright © <strong>Infineon</strong> Technologies 2010. All rights reserved.<br />
Page 21
PFC, functional details<br />
+<br />
-<br />
Confidential Copy<br />
Confidential Copy<br />
2010-01-14 Copyright © <strong>Infineon</strong> Technologies 2010. All rights reserved.<br />
Page 22
PFC, functional details<br />
+<br />
-<br />
Confidential Copy<br />
Confidential Copy<br />
2010-01-14 Copyright © <strong>Infineon</strong> Technologies 2010. All rights reserved.<br />
Page 23
PFC, functional details<br />
+<br />
-<br />
Confidential Copy<br />
Confidential Copy<br />
2010-01-14 Copyright © <strong>Infineon</strong> Technologies 2010. All rights reserved.<br />
Page 24
PFC, functional details<br />
+<br />
-<br />
Confidential Copy<br />
Confidential Copy<br />
2010-01-14 Copyright © <strong>Infineon</strong> Technologies 2010. All rights reserved.<br />
Page 25
OBC solution rev. 1.0 in operation,<br />
lab measurements at PFC<br />
Confidential Copy<br />
Zoom to the moment in time<br />
when line voltage is at 180V<br />
zero voltage switching :<br />
Gate(red) and Drain(green)<br />
Confidential Copy<br />
2010-01-14 Copyright © <strong>Infineon</strong> Technologies 2010. All rights reserved.<br />
Page 26
OBC solution rev. 1.0 in operation,<br />
lab measurements at PFC<br />
Confidential Copy<br />
Zoom to the moment in time<br />
when line voltage is at 230V<br />
zero voltage switching :<br />
Gate(red) and Drain(green)<br />
Confidential Copy<br />
2010-01-14 Copyright © <strong>Infineon</strong> Technologies 2010. All rights reserved.<br />
Page 27
Schematic Diagram of LLC, p1<br />
Confidential Copy<br />
Confidential Copy<br />
2010-01-14 Copyright © <strong>Infineon</strong> Technologies 2010. All rights reserved.<br />
Page 28
Schematic Diagram of LLC, p2<br />
Confidential Copy<br />
Confidential Copy<br />
2010-01-14 Copyright © <strong>Infineon</strong> Technologies 2010. All rights reserved.<br />
Page 29
OBC solution rev. 1.0 in operation,<br />
lab measurements at LLC<br />
power transfer is controlled by<br />
tuning the frequency ..<br />
Confidential Copy<br />
.. in the neighbourhood of<br />
the resonant point<br />
zero voltage switching :<br />
Gate(green) and Drain(red)<br />
Confidential Copy<br />
2010-01-14 Copyright © <strong>Infineon</strong> Technologies 2010. All rights reserved.<br />
Page 30
Programmable Logic Device implements<br />
power converter control loop<br />
Confidential Copy<br />
Sample Time: ~0,4us(LLC), Control Time constant: 10us, Gain = 100<br />
Confidential Copy<br />
2010-01-14 Copyright © <strong>Infineon</strong> Technologies 2010. All rights reserved.<br />
Page 31
Resonant PFC: patent pending<br />
US 2009/0302814 Kapels, Deboy<br />
Confidential Copy<br />
Confidential Copy<br />
2010-01-14 Copyright © <strong>Infineon</strong> Technologies 2010. All rights reserved.<br />
Page 32
Use of Superjunction devices such as CoolMOS<br />
is IP protected in all major applications<br />
Confidential Copy<br />
Confidential Copy<br />
US RE40,352<br />
Deboy et al<br />
granted June 3, 2008<br />
2010-01-14 Copyright © <strong>Infineon</strong> Technologies 2010. All rights reserved.<br />
Page 33
Use of Superjunction devices such as CoolMOS<br />
is IP protected in all major applications<br />
Confidential Copy<br />
Confidential Copy<br />
US US 6,819,089 RE40,352<br />
Deboy Deboy et al et al<br />
Granted granted Nov June 16, 2004 3, 2008<br />
2010-01-14 Copyright © <strong>Infineon</strong> Technologies 2010. All rights reserved.<br />
Page 34
Use of Superjunction devices such as CoolMOS<br />
is IP protected in all major applications<br />
Confidential Copy<br />
Confidential Copy<br />
US 6,664,590<br />
Deboy et al<br />
Granted Dec 16, 2003<br />
2010-01-14 Copyright © <strong>Infineon</strong> Technologies 2010. All rights reserved.<br />
Page 35
Use of Superjunction devices such as CoolMOS<br />
is IP protected in all major applications<br />
Confidential Copy<br />
Confidential Copy<br />
Switch mode power supply<br />
with transistor characterized<br />
by non-linear output capacitance<br />
Power factor correction stage<br />
utilizing Superjunction devices<br />
Bridge configuration with at least<br />
one Superjuntion device<br />
2010-01-14 Copyright © <strong>Infineon</strong> Technologies 2010. All rights reserved.<br />
Page 36
<strong>Infineon</strong> OBC solution, Target Spec.<br />
Single Phase AC supply<br />
Confidential Copy<br />
Active bridgeless PFC with wide range, Imax=16A (rms)<br />
Input Voltage range from 90 V to 264V (AC)<br />
Power Factor > 99%<br />
Total Efficiency > 94 % @ 230 VAC (> 90% @ 115V)<br />
galvanic isolation<br />
µ-controller based system architecture<br />
mutual supervision µC PLD<br />
ambient temperature -40 - .. +85°<br />
water cooling<br />
sealed housing IP6k7 / IP6k9k<br />
Volume < 4,5 litres<br />
Confidential Copy<br />
2010-01-14 Copyright © <strong>Infineon</strong> Technologies 2010. All rights reserved.<br />
Page 37
virtual view of die-cast case with<br />
OBC-hardware inside<br />
volume below 4 litres<br />
water cooling<br />
safety class IP6k7/IP6k9k<br />
Confidential Copy<br />
Confidential Copy<br />
2010-01-14 Copyright © <strong>Infineon</strong> Technologies 2010. All rights reserved.<br />
Page 38
eal photograph of die-cast case : water-cooled<br />
aluminium body and transparent cover<br />
Confidential Copy<br />
Confidential Copy<br />
2010-01-14 Copyright © <strong>Infineon</strong> Technologies 2010. All rights reserved.<br />
Page 39
virtual view into coolant compartment of<br />
aluminium body<br />
Confidential Copy<br />
Confidential Copy<br />
2010-01-14 Copyright © <strong>Infineon</strong> Technologies 2010. All rights reserved.<br />
Page 40
virtual view of OBC hardware with<br />
aluminium body removed<br />
Confidential Copy<br />
Confidential Copy<br />
2010-01-14 Copyright © <strong>Infineon</strong> Technologies 2010. All rights reserved.<br />
Page 41
Layout of PFC board, rev1.1<br />
Confidential Copy<br />
200mm<br />
Confidential Copy<br />
2010-01-14 Copyright © <strong>Infineon</strong> Technologies 2010. All rights reserved.<br />
Page 42<br />
95mm
Layout of LLC board, rev1.1<br />
Confidential Copy<br />
200mm<br />
Confidential Copy<br />
2010-01-14 Copyright © <strong>Infineon</strong> Technologies 2010. All rights reserved.<br />
Page 43<br />
63,5mm
η<br />
our OBC solution : evaluation results,<br />
Total Efficiency<br />
Confidential Copy<br />
Confidential Copy<br />
2010-01-14 Copyright © <strong>Infineon</strong> Technologies 2010. All rights reserved.<br />
Page 44<br />
P
photo of OBC hardware in die-cast case<br />
Confidential Copy<br />
Confidential Copy<br />
2010-01-14 Copyright © <strong>Infineon</strong> Technologies 2010. All rights reserved.<br />
Page 45
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