Power Electronics in Electrics and Hybrid Vehicles : Market Research Report

Power Electronics in Electrics and Hybrid Vehicles

Published: Oct. 1, 2009 - 166 Pages

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

This report presents the detailed major market metrics of the current and projected HEV/EV power module, power devices and substrate business.

The HEV and EV power electronics market is booming & may use SiC or GaN technologies before 2020

Toyota, the world leading car producer has been dominant on the hybrid market up to now, but this niche market is becoming a must for car makers as the focus on car C02 emissions intensifies. Hybrid is defined in different levels: micro, mild, full, and plug in hybrid.

Micro hybrid will see the highest growth due to its low cost and easy integration, specifically in Europe. Mild and full hybrid will continue their strong penetration in the US market. Plug-in hybrid is a bridge to EV technology, and uses the same high voltage battery technology and plugto- grid for recharge.

EV car business will really ramp up in 2010 with the arrival of big car makers (Mitsubishi, Renault, GM, Ford, Daimler). Limited drive range (40 miles) and high cost, are still issues, but it is expected that huge investments in new Li-Ion batteries will increase the performance/cost ratio of EVs. Globally, more than 17 million cars will be hybrid or electric in 2015 and some forecasters suggest sales will reach 50 million units in 2020, meaning half of the cars produced.

Power electronics are a key technology for hybrids and represent 20% of the material costs. It is even bigger for EV cars. HEV/EV power devices are used in DC/DC converters and DC/AC inverters. There are various configurations depending on the hybrid version and car makers’ choices.

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Power Electronics in Electrics and Hybrid Vehicles

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Abstract