Automotive Traction Inverters: Current Status and Future Trends

Reimers, John; Dorn-Gomba, Lea; Mak, Christopher; Emadi, Ali

doi:10.1109/tvt.2019.2897899

Cited by 244 publications

(104 citation statements)

References 88 publications

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“…The core components in power electronics devices are the semiconductor dies. Currently, Si Insulated Gate Bipolar Transistors (IGBTs) are widely implemented in power semiconductor devices for electrified transportation applications [20]. Off-the-shelf products also include silicon carbide (SiC) Metal Oxide Semiconductor Field Effect Transistor (MOSFET) based power modules and discrete devices, with the latter being implemented in Tesla's Model S and X [21].…”

Section: Packaging Fundamentalsmentioning

confidence: 99%

Automotive Power Module Packaging: Current Status and Future Trends

et al. 2020

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Semiconductor power modules are core components of power electronics in electrified vehicles. Packaging technology often has a critical impact on module performance and reliability. This paper presents a comprehensive review of the automotive power module packaging technologies. The first part of this paper discusses the driving factors of packaging technology development. In the second section, the design considerations and a primary design process of module packaging are summarized. Besides, major packaging components, such as semiconductor dies, substrates, and die bonding, are introduced based on the conventional packaging structure. Next, technical details and innovative features of state-of-the-art automotive power modules from major suppliers and original equipment manufacturers are reviewed. Most of these modules have been applied in commercial vehicles. In the fourth part, the system integration concept, printed circuit board embedded packaging, three-dimensional packaging, press pack packaging, and advanced materials are categorized as promising trends for automotive applications. The advantages and drawbacks of these trends are discussed, and it is concluded that a preferable overall performance could be achieved by combining multiple technologies. INDEX TERMS Electric vehicles, power electronics, semiconductor device packaging TABLE I PRIMARY DESIGN CONSIDERATIONS OF MODULE PACKAGING Design considerations Details Size Volume, weight, power density, energy density. Electrical performance Current rating, voltage rating, switching frequency range, power loss, electrical insulation, electromagnetic interference (EMI). Thermal management Temperature distribution, thermal resistance (Rth), heat capacity, coefficient of thermal expansion (CTE). Mechanical strength Thermal stress distribution, material properties (Tensile strength, flexural strength, peel strength, etc.), external shock and vibration. Reliability and fatigue Joints failure, crack propagation, delamination, lifetime under temperature and power cycling. Manufacturability and assembly Manufacture procedure, process temperature and pressure, external connections.

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Section: Packaging Fundamentalsmentioning

confidence: 99%

Automotive Power Module Packaging: Current Status and Future Trends

et al. 2020

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“…The electric machine used was a 65-kW axial flux SM-PMSM (EVO AF-130). The DC-link incorporated a C DC of 700 µF, and the battery pack had a rated voltage of 320 V. Each inverter switch was formed by four parallelized automotive-grade discrete IR AUIR-GPS4067D1 devices (TO-247 package), as such devices constitute a representative example of the power device technologies used in current EVs [18]. Once again, the switching frequency was set at 10 kHz for the same reason justified in Section 4.1.…”

Section: Vsizvr-d2 Topology Performance During Realistic Driving Condmentioning

confidence: 99%

“…The most relevant capacitive paths are depicted in Figure 2, where the most significant bearing currents produced by CMV are the capacitive currents, electrostatic discharge currents, circulating currents, and rotor ground currents [9,13]. As bearings are critical components for the electric machine [10], a number of industrial companies are currently analyzing the degradation problems generated by such bearing currents [15][16][17].Regarding this issue, it is important to remark that although the majority of current industrial solutions rely on silicon-based semiconductor technologies [18], the progressive introduction of new wide bandgap (WBG) semiconductor devices in automotive power converters is expected [19]. This will allow significantly increasing the operating switching frequencies when compared to conventional insulated gate bipolar transistor (IGBT) based Si technologies.…”

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confidence: 99%

“…Regarding this issue, it is important to remark that although the majority of current industrial solutions rely on silicon-based semiconductor technologies [18], the progressive introduction of new wide bandgap (WBG) semiconductor devices in automotive power converters is expected [19]. This will allow significantly increasing the operating switching frequencies when compared to conventional insulated gate bipolar transistor (IGBT) based Si technologies.…”

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Mitigation of Common Mode Voltage Issues in Electric Vehicle Drive Systems by Means of an Alternative AC-Decoupling Power Converter Topology

et al. 2019

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Electric vehicles (EV) are gaining popularity due to current environmental concerns. The electric drive, which is constituted by a power converter and an electric machine, is one of the main elements of the EV. Such machines suffer from common mode voltage (CMV) effects. The CMV introduces leakage currents through the bearings, leading to premature failures and reducing the propulsion system life cycles. As future EV power converters will rely on wide bandgap semiconductors with high switching frequency operation, CMV problems will become more prevalent, making the research on CMV mitigation strategies more relevant. A variety of CMV reduction methods can be found in the scientific literature, such as the inclusion of dedicated filters and the implementation of specific modulation techniques. However, alternative power converter topologies can also be introduced for CMV mitigation. The majority of such power converters for CMV mitigation are single-phase topologies intended for photovoltaic applications; thus, solutions in the form of three-phase topologies that could be applied to EVs are very limited. Considering all these, this paper proposes alternative three-phase topologies that could be exploited in EV applications. Their performance is compared with other existing proposals, providing a clear picture of the available alternatives, emphasizing their merits and drawbacks. From this comprehensive study, the benefits of a novel AC-decoupling topology is demonstrated. Moreover, an adequate modulation technique is also investigated in order to exploit the benefits of this topology while considering a trade-off between CMV mitigation, efficiency, and total harmonic distortion (THD). In order to extend the results of the study close to the real application, the performance of the proposed AC-decoupling topology is simulated using a complete and accurate EV model (including vehicle dynamics and a detailed propulsion system model) by means of state-of-the-art digital real-time simulation.Energies 2019, 12, 3349 2 of 27 the commutations of the power converter devices generate significant high-frequency CMV variations (Figure 1a). As a result, these voltage variations can produce not only high electromagnetic interferences (EMI) [6][7][8], but also shaft voltages (Figure 1b) in the electric machine [9][10][11], producing new capacitive paths [10]. These paths result in high-frequency leakage currents (Figure 1c) circulating through the motor bearings [12][13][14]. The most relevant capacitive paths are depicted in Figure 2, where the most significant bearing currents produced by CMV are the capacitive currents, electrostatic discharge currents, circulating currents, and rotor ground currents [9,13]. As bearings are critical components for the electric machine [10], a number of industrial companies are currently analyzing the degradation problems generated by such bearing currents [15][16][17].Regarding this issue, it is important to remark that although the majority of current industrial solutions rely on silicon-bas...

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“…In this context, static power converters can more easily allow for bidirectional power flow while helping to maintain overall grid stability, by employing a wide array of control techniques [2]. The pervasive electrification of the transportation sector is also driving up power electronics complexity, for both cars [3] with the introduction of hybrid and electric vehicles, and aircraft [4]. In fact, the More Electric Aircraft (MEA) [5] framework aims to replace the mechanical, hydraulic, and pneumatic systems with electromechanical ones.…”

Section: Introductionmentioning

confidence: 99%

Minimization of Network Induced Jitter Impact on FPGA-Based Control Systems for Power Electronics through Forward Error Correction

et al. 2020

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In modular distributed architectures, the adoption of a communication method that is at the same time robust and has a low and predictable latency is of utmost importance in order to support the required system dynamics. The aim of this paper is to evaluate the consequences of the random jitter on machine drives distributed control, caused by the messages’ re-transmission in case of an error in the received data. To achieve this goal, two different Forward Error Correction (FEC) techniques are introduced in the chosen protocol, so that the recipient of the message can correct random errors without the need of any additional round trip delays needed to request and obtain a re-transmission. Experimentally validated simulations are used to evaluate the impact of random network derived jitter on a real world closed loop control system for distributed power electronic converters.

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Automotive Traction Inverters: Current Status and Future Trends

Cited by 244 publications

References 88 publications

Automotive Power Module Packaging: Current Status and Future Trends

Automotive Power Module Packaging: Current Status and Future Trends

Mitigation of Common Mode Voltage Issues in Electric Vehicle Drive Systems by Means of an Alternative AC-Decoupling Power Converter Topology

Minimization of Network Induced Jitter Impact on FPGA-Based Control Systems for Power Electronics through Forward Error Correction

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