Power Electronics in Electrics and Hybrid Vehicles

Published by: Yole Developpement

Published: Oct. 1, 2009

Table of Contents

Methodology, limitations and Yole proprietary tools

Glossary

Executive summary

HEV types and availability: Micro, Mild, Full, plug in Hybrid and Electric

HEV/EV incremental cost, versus benefit

HEV/EV principles : a wide and complex range of functionalities

HEV/EV configurations and power devices applications

HEV/EV power electronics applications : devices types and power level

Power module value in $ per hybrid application in 2009

EV and HEV annual demand forecast to 2020 in Munits Split: Micro Hybrid and others EV/HEV

Power module price roadmap split by HEV/EV application

Power module revenues in $M for HEV/EV applications to 2020

IGBT and MOSFET power modules revenues by applications

Silicon wafers consumption forecast for HEV/EV power modules (Munits of 6” equiv.)

Power electronics applications in HEV/EV

Bill of Material in HEV complete electric power-train

Current device technologies in use

Micro Hybrid start-stop

Mild Hybrid converters and inverters

DC/DC converter 14 V (full hybrid + plug in + EV)

DC/AC inverter + DC/DC booster option (full hybrid, plug-in, EV)

Plug In and EV battery charger (AC/DC)

HEV Market

Top 20 motor vehicle companies in 2008

Hybrid car sales today

Industry involvement: HEV car manufacturers

Worldwide hybrid car projections: Geographical trends

Hybrid car launch: 47 available models expected for 2011

HEV/EV Market

Electric technology

Plug-in HEV (PHEV): a bridge technology to EV

Plug in HEV (PHEV) models introduction: large commercialisation after 2010

EV models introduction: big players in the starting blocks

PHEV / EV : Li Ion battery is a must…but who will afford it?

Key players in Li Ion batteries

Better place EV service provider : a solution to expensive and limited range batteries?

EV better place project

Better place EV service provider: a solution to expensive batteries?

EV infrastructure

Fuel Cell Vehicle (FCV) : a possible option after 2015

Plug in and EV challenges

HEV architectures and power control units

Different HEV architectures: Series / Parallel / Split

Different HEV architectures: Toyota Prius II HEV engine cross sectional view

Current HEV architectures

Toyota Prius electric components roadmap

Overview of Toyota power control unit for Prius 2003

Overview of Toyota power control unit for Prius GS 450 h (2006)

Overview of Toyota power control unit (PCU) for Lexus Sedan LS 600 h (2007) manufactured by Denso (JP)

Honda power control unit evolution

GM Hybrid 2 mode solution

Power electronics challenges and industrial supply chain

Challenges for inverter suppliers in HEV/EV

Power module price roadmap split by HEV/EV

Example of traditional power modules design

Inverter cooling design: 2D approach

Inverter cooling design: 3D cooling new approach to save space

Inverter design : a trend for a stronger mechatronics integration

Many alliances in 2009 between car players and power players on HEV/EV power electronics

Industrial supply-chain and typical market prices from modules to power train

HEV power devices Industrial Supply-Chain: From discrete to vehicles, a worldwide coverage

HEV inverter module cost breakdown

Industrial supply-chain trends

Players, latest developments: Automotive tier one suppliers

Automotive tier one suppliers position

European HEV tier one suppliers : BOSCH

European HEV tier one suppliers : CONTINENTAL

European HEV tier one suppliers : Valeo

European HEV tier one suppliers : Magna Electronics

US HEV tier one suppliers : Delphi

Asian HEV tier one suppliers : Hitachi

Asian HEV tier one suppliers : Denso

SiC & GaN as Silicon substitute?

Why SiC or GaN in cars ?

2 key power modules: DC-DC boost converter and DC-AC inverter

Expected improvements of SiC or GaN introduction in HEV

The TOP 5 key requirements for power transistors in HEV

Roadmap for operation voltage in HEV

Added value analysis of SiC electronics for HEV: fuel consumption and money savings

Silicon vs. SiC HEV inverter cost breakdown

Sales projection for Silicon and SiC devices in EV/HEV inverters

4” and 6” SiC substrate volume projection for SiC devices in HEV

SiC & GaN device suppliers - car manufacturers relationships

SiC device voltage range covered by main companies (Prod. or R&D)

Example of GaN Hybrid MOS-HFET by Furukawa Electric

Example of GaN HEMT by Fujitsu

Example of GaN-based power FET by Panasonic

Matsushita MEI / Panasonic: 10kV GaN high-voltage HEMT

Matsushita MEI / Panasonic: GaN high-voltage “Natural Super Junction” diode

AlGaN/GaN HEMT on n-SiC by Toshiba

AlGaN/GaN HEMT by Toyota R&D Lab

5” GaN-on-Si FET by Sanken Electric

Hong Kong University of Science & Technology (HKUST) GaN-on-Si integrated diode + transistor

International Rectifier GaNpowIR™ technology platform

Conclusion: perspective for SiC and GaN devices in the HEV

Silicon, SiC & GaN device and module recent developments

European players

Asian players

US players

Abstract

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