電動車電源發展趨勢與展望

張育銘
台達電子
Oct. 30th 2018
 Content

 Macro View of EV Development

 Power Management in EV

 EV Charger Development

 Summary

2
Macro View of EV Development
 Megatrends
Powertrain Electrification Powertrain Modularity
& Light Weighting

GM Gen II
Traction motor

Connected &
Road Safety—ADAS Automated Driving

Advanced Driver Assistance Systems

4 Source: Frost & Sullivan, McKinsey, Goldman Sachs

 Global EV Stock

5
 Overview
 China
In 2017, the sales of new energy passenger vehicles were 560,000 units,
increased more than 70% from 320,000 units in 2016.
 EU
Plug-in vehicle sales in Europe were 306K units in 2017, 39% higher than for
2016.
 US
In 2017, BEVs were over 100,000 units. Plug-in hybrid were just behind at 90,000
units.
 Powertrain
– Motor power range of 60-99kW is the most popular rating.
– xEV motors 4.8Mn units in 2016 to 27.4Mn units in 2025, at a CAGR of 21.3%.
 Charging Infrastructure
The global EV charging infrastructure market was USD 1,160.7 million in 2016
and will expect to be USD 45,596.6 million by 2025, (CAGR of 46.8% from 2017
to 2025 Asia Pacific and Europe will be the key regional markets

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 EV Cost Parity Timing

7
 EVs
EV (BEV) PHEV
Power Inverter

370kW/450km Tesla Model S 120kW/1030km/64km GM Volt

HEV FCV

Toyota Prius 100kW/700km Toyota Mirai

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Global EV stock by scenario, 2017-30

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 Powertrain Development Trend
 Address cost concern of EV/HEV
 Tech development toward higher integration and increased power density

10
 Key to reduce EV energy consumption:
increase efficiency of drive system

Major players competing to develop “integrated” drive system

 Integrate motor, power electronics, and transmission into one compact unit
 Remove power connector and three-phase cable
 Liquid cooled technology

High efficient, low cost and compact

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 Energy consumption of BEV
Vehicle energy-saving is one of the core technologies in the EV market

Lightweight

Efficient
Low resistance
driving Technologies of
reducing energy
consumption

Heat pump Energy

air-conditioning recovery

Goal of national new energy vehicle research & develop program in 2020: energy consumption
of battery electric vehicle (length ≥ 4.5m) is lower than 10 kWh/100 km (under NEDO)
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 Power Density Challenge in EV/HEV
 Cost of EV/HEV systems is not yet competitive compared to internal combustion engines.
 To reach significantly lower cost, a considerable investment in needed in technology,
integration with other vehicle systems, cross platform sharing, etc.
Whole Traction Drive Systems Power Electronics Motors
Year Cost$/kW kW/kg kW/L Efficiency Cost$/kW kW/kg kW/L Cost$/kW kW/kg kW/L

2010 19 1.06 2.6 >90% 7.9 10.8 8.7 11.1 1.2 3.7

2015 12 1.2 3.5 >93% 5 12 12 7 1.3 5

2020 8 1.5 3.5 >94% 3.3 14.1 13.4 4.7 1.6 5.7

2025 5 1.6 5 >95% 2.1 15.8 17.6 2.9 1.7 7.4

Challenges

Traction Drive System Power Electronics Electric Motors

• Benchmarking technologies
• Innovative systems designs
• Innovative topologies
• Temperature-tolerant devices
• Packaging
• Capacitors
• Vehicle charging
• New materials
• Permanent magnet (PM) motors
• Magnetic materials
• High-performance of non-PM motors
• Thermal system integration
• Heat transfer technologies
• Thermal stress and reliability

Key drivers for innovations in power electronics :

Weight reduction Volume reduction Cost reduction
Source: Yole Développement(2016),
13 What does the future of automotive market hold?
Power Electronics in EV Development
Power Electronics Technology

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Future Drive Trend Configuration

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 EV Power Product
Motor drive On-board Charger DCDC Aux. Power

EV fast charge Battery

Motor 48V DCDC HV Junction box
controller Contactor Unit
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 Power Control Unit

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 Power Control Unit

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 SiC devices Bring High Efficiency
Switching
80 CAS325M12HM2
Eon
i.e. 100kW, 10kHz
Eoff
60 Err Switching Losses
FF300R12KT4
Eon Conduction Losses
ES / mJ

Eoff
40 Err

20
~1/3 75%

Total Loss
0
0 100 200 300 400 500
I/A
Conduction
500

400

300
I/A

200 ~1/2 Si IGBT SiC MOSFET

CAS325M12HM2 25℃
100 CAS325M12HM2
FF300R12KT4
150℃
25℃ 5~10% mileage increased
FF300R12KT4 150℃
0
0.0 0.5 1.0 1.5 2.0 2.5 3.0
V/V
SiC MOS is a very effective solution to increase mileage for high performance EV
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 Onboard Charger
 Input voltage: 80V – 240V AC
 Output Voltage: 240V – 430V DC

 Power Levels
 3.3 … 3.7kW
 6.6 … 7.2kW
 9.6 … 11kW

 Efficiency: 94-95%

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 Battery Disconnect Units
 Fast Charging Module

 Battery Disconnect

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 Tesla Model S

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 Tesla Model 3

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 Tesla Model S Power Train

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 Tesla Model 3 Power Train

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 Tesla Model 3 Power Train

減速器差速器

電機

1. 電機、電控和減速器高度集成
2. 電控單元占整個 power train 的體積比小

Delta Confidential
 Tesla Model 3 Power Train

AC端口

功率模組

電控介面

1. 佈置緊湊，XY 方向儘量利用空間，
Z 方向尺寸嚴格控制
DC端口 电容
2. 扁平化佈置，組件配合殼體定制
3. 無螺栓連接，節省空間，降低重量

Delta Confidential
 Tesla Model 3 Power Train

1. 厚銅特殊 DBC 結構的單面散熱

2. 主回路 pin 腳採用鐳射焊接
3. Ag 燒結集成散熱器水冷技術

厚铜DBC

Delta Confidential
 Tesla Model 3 Power Train

1、MCU：TI TMS320F28377DPTPQ
2、SIC FETS：ST GK026
3、Gate Driver：STGAP1AS
4、Resolver Amp：On Semi TCA0372BDW
5、EEPROM：Microchip 25LC256E
6、CAN Transceiver： TI SN65HVD1040
7、LIN Transceiver：NXP TJA1021
8、HV Sense：Broadcom ACPL-C87BT-000E
9、SBC：TLF35584QVVS2
10、DCDC Transformer：TDK VGT22EPC-222S6A12

Delta Confidential
 Tesla Model 3 Power Train

• Bulk Cap：nichicon 550uF+0.68uF+0.68uF,430VDC 30*260*65mm

Delta Confidential
 Tesla Model S/3 Batteries

18650 2170

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 Level 4 Driverless Car

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Driverless Car Charging Contact

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Power Electronics in EV Charger Development
 Charging Technology

AC EVSE DC quick charger DC super Inductive Charger Robotic charger

fast charger

On board charger

Convenient
Residential Residential Coffee to charge Good with auto Auto charging
Work place Work place Public Parking and
Public Public charging system

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 China’s vision on EV charging technology
Development of charging technology will be vehicle-to-grid based. Compatible integrate
EV with the distributed energy resources into a micro-grid to ensure load balance.

AC charging Fast charging

Medium
On-board Off-board On-board
voltage
(V2G) high-power
Charger AC grid Charger AC grid
wireless charging fast charging
EV Microgrid EV

7-22kW 120-350kW
80% 15%

Next 2-3yr Next 3-5yr Next 5-10yr

Charging Day: 30 min (40%SOC) Day: 30 min (60%SOC) Day: 15 min (75%SOC)
time Night: 5-8 hours Night: 5-8 hours Night: 5-8 hours
Public charging station, Public charging station (power Public charging station, fast
Location fast charging station balancing), fast charging station charging station near freeway,
near freeway, taxi stand near freeway, fleet charging fleet charging
Mainly charging at night, Mainly charging at night, Mainly charging at night,
Charging opportunity charging in opportunity charging in the opportunity charging in the
scenario the daytime daytime, and fast charging for daytime, ultra-fast charging for
longer trip longer trip, and power exchange
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 Tesla Super Charging Station Layout
480/720kW station, 4/6 charger, 8~12 pole
C: Charger breaker
135kWcharger
Charging pole
12kV/480V TX

>33m2, 5500kg
A:Input

B: Metering &
5m2, 1800kg main breaker 1.5m2, 600kg x 4

6.2m2, 1300kg

A
B distribution
C
TX
TX pole charger

 Large transformer, special enclosure

 Labor intensive installation
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 Ultra Fast Charging status
US and European automakers are planning to enlarge battery capacity to
100kWh in 2020, the driving range can up to 500 km. Therefore it requires
350kW to charging within 15-min.

North America
EVgo and ABB announced to deploy Nation’s first high-power electric vehicle
fast charging station. The installed system has the potential to reach charging
speeds of up to 350kW with an upgrade.

Europe
IONITY have announced a collaboration to build 400 High-Power charging
stations (350kW) throughout Europe by 2020.

Japan
Industry plans to provide 350 kW fast charger starting in 2020

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 Ultra density high power charging station

MV transformer

Non-isolated
Joint-venture AC/DC charging
station
Charge point

Plan to build 400 charging parks (typically 2400 high power charging stations) throughout the Europe highway
networks by Y2020

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 High power charging station architecture
U6
AC DC

AC Heat exchanger
contactor
3Φ AC
480Vac DC

SPD AC
DC
DC
contactor AC
DC
800Vdc
AC
DC
GFD
AC
Key innovation point
DC
1. Very high density (45W/inch3) and very high
AC efficiency (98%) 68KW charging module
DC
Ethernet ECU 2. Modular design, salability and flex system
integration capability
Liquid 3. non-isolated converter parallel and
In & outlet
redundancy capability
Delta Confidential 41
 68KW Charging Module Internal Structure
Control BD PFC choke BD AC filter cap
EMI filter BD

Liquid cooled 68KW charging

module advantage

1. High efficiency: up to 98%, over 97%

@ 10~100% load range
2. High density: 49W/inch3
3. Wide output range: 150V~950V
3. Dust and salt protected
4. Maintain free

Bulk cap BD DC/DC choke BD DC filter cap Oring diode module

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 SIC power module
Vienna PFC Full bridge
Module Module

Infineon
version D11
Q1 Q3
Q2
D1

Q3
D2 Q2 Q4

Vincotech D12
version

Benefit:
High reliability
High speed and very low switching loss
Better efficiency and much smaller size for converter
Much lower EMI noise duty to parasitic control
and capacitor integration

Result:
Both 68KW charging module and 350KW charging station
Meet the IEC and FCC class B requirement 43
Delta Confidential
 EV Charging Infrastructure w DER

Functions
 Energy Management
Utility Smart Local EMS  Peak Shaving
Power Grid Transformer Meter
 Frequency Regulation
Local EMS  PV Smoothing
Smart Meter
Distribution PV Inverter
 PQC
Panel MW Inverter  Load Shifting
Breaker EV Charger  Black Start
PCS + Battery  Smart Grid Support
PCS EV Charger

10～22KW >150KW PV Inverter Solar Panel

Modbus RTU
IEC 61850/DNP3
VPN Server
Modbus RTU
Site Controller

200-900Vdc
Battery E-Vehicle
Environment Energy Management
AC Power DC Power Comm. HMI
Controller System (EMS)
Grid Operator

Delta Confidential 44
 SST- Based Fast Charging Solution

Smart Grid

Smart Functions
Power Grid
Meter
Local EMS  Peak Shaving
 Load Shifting
Local EMS  PQC
Smart Meter  Black Start
SST  Smart Grid Support
DC/DC converter
DC EV Charger
DC ESS User Portal
DC PCS DC EV Charger DC MPPT

MW 10～22KW >150KW DC/DC Converter Solar Panel

Modbus RTU
IEC 61850/DNP3
VPN Server
Modbus RTU
Site Controller

200-900Vdc
Battery E-Vehicle
Environment Energy Management
AC Power DC Power Comm. HMI
Controller System (EMS)
Grid Operator

Delta Confidential 45
 Summary

 Driver-less Taxi will start to operate from 2019 and it might impact on
the car volume for the future and those companies are used battery EV

 PEV will continue to grow and to replace the ICE vehicles

 Battery, DC/DC converter, Power Control Unit are the most important
parts for power electronics product

 Wide bang gap (WBG) component has starting use in EV to reduce the
size, weight and increase the efficiency

 Packaging technology will become much more importance to fully utilize

WBG strength

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