11

Raising the safety and the reliability of power system and electronic system of electric vehicle加強提升電動汽車動力系統和電子系統之安全性和可靠性

2018/04/13

22

OUTLINE Concept of Electric Vehicles Power System

– 10 min Electric Vehicles Electronic System design

– 5 min Harsh Environment Test for Automotive Requirement

– 10 min Enhance Electric Circuit Design In Protection For Raising Safety And

Reliability– 10 min

Q&A– 5 min

33

EVs Category

1. Concept of Electric Vehicles Power System

A: EVs Charging Association & Protocols

5555

SAE J1772 (AC) CCS COMBO (AC & DC)

Support EVSE protocol

AC level 1: is 120V and peak current up to 16A with single phase transferring. The maximum power could be reached 1.92KW.

AC level 2: is 240V and peak current up to 80A with split phase transferring. The maximum power could be reached 19.2KW.

Added DC power and Ground Support EVSE protocol

DC level 1: is 200~500VDC and peak current up to 80A. The maximum power could be reached up to 40KW.

DC level 2: is 200~500VDC and peak current up to 200A. The maximum power could be reached up to 200KW.

6666

CHAdeMO is an e-mobility collaboration platform around CHAdeMO DC charging protocol. As an ecosystem of companies offering CHAdeMO-related products and services we work together to promote and enable electric mobility on a global scale.

This standard is to provide a kind of quick charging method for EVs battery and deliver power up to 200KW (500Vdc/400A) with special inlet connector.

50KW DC charging station could provide 200Km per hour of charging.

Source from CHAdeMo

7777

Source from CHAdeMo

8888

Source from WWW

99

Wireless Charging for EVs

Source from HELLA

1010

On-board VS Off-board Charging

Picture from ABB

Off-BoardCharger

• Cheaper charging station• Slowly charging time• Suitable for home/private place• Temporary feature for EV application

• Expensive charging station• Quickly charging time• Suitable for public place • KEY for popularized

EVs battery only support HVDC(~400VDC) input

<20KW & Small Size >40KW & DC Fast Charger

1111

12V Lead Acid

Battery

48V Li IonBattery

µCCM

High V Li Ion Battery Pack

CM CM

CM CM

µC

µC

BMS / Charge Controller

DC DC Converter

On Board Charger

120V / 250V AC

~400VDC

Electric Motor

Electric Coolant Pump

PTC Heater

Electric Vacuum Pump

• Infotainment• ADAS Systems• Other LV Systems

Junction Box 1

CombustionEngine

Generator

Contactor

DC AC Inverter

A/C Compressor

DC DC Converter

Electric Power Steering

Junction Box 2

AC PowerDC Power

EVs On Board Charger Architecture

1212

EVs Charging Key Components

Junction Box

BMS

High Li ion Batteries

AC/DC inverter

1. Concept of Electric Vehicles Power SystemB: EVs Battery Powertrain Delivery

1414

EVs Powertrain System(1)

HVDC Output3-Phase AC Output

Horsepower Output

1515

EVs Powertrain System(2)

12V Lead Acid

Battery

48V Li IonBattery

µCCM

High V Li Ion Battery Pack

CM CM

CM CM

µC

µC

BMS / Charge Controller

DC DC Converter

On Board Charger

120V / 250V AC

DC

Electric Motor

Electric Coolant Pump

PTC Heater

Electric Vacuum Pump

• Infotainment• ADAS Systems• Other LV Systems

Junction Box 1

Combustion Engine

Generator

Contactor

DC AC Inverter

A/C Compressor

DC DC Converter

Electric Power Steering

Junction Box 2 Brakes

2. Electric Vehicles Electronic System Design

1717

EV / PHEV ArchitectureMain Building Blocks

12V Lead Acid

Battery

48V Li IonBattery

µCCM

High V Li Ion Battery Pack

CM CM

CM CM

µC

µC

BMS / Charge Controller

DC DC Converter

On Board Charger

120V / 250V AC

DC

Electric Motor

Electric Coolant Pump

PTC Heater

Electric Vacuum Pump

• Infotainment• ADAS Systems• Other LV Systems

Junction Box 1

Combustion Engine

Generator

Contactor

DC AC Inverter

A/C Compressor

DC DC Converter

Electric Power Steering

Junction Box 2

18181818

Automotive Electronic Systems Design

3. Harsh Environment Test for Automotive Requirement

2020

Suitable For Harsh Environment Driving

2121

Automotive Electronics Failure Analysis1. Endurance(耐受度)

– System Stress Endurance Temperature Humidity Vibration Collision

2. Loading & Transient (過載與暫態電壓)– Over Loading Conditions

Overcurrent– Transient & Human Body Electrostatic Discharge(ESD)

Overvoltage

2222

Failure Mechanism Based Stress Test Qualification The Automotive Electronics Council (AEC) was originally established by Chrysler, Ford, and

GM for the purpose of establishing common part-qualification and quality-system standards. – Quality Systems Committee : Created the standardize of the quality system of suppliers

(ISO/TS 16949)。– Component Technical Committee : To establishing standards for reliable, high quality

electronic components. Components meeting these specifications are suitable for use in the harsh automotive environment without additional component-level qualification testing.

Other Reliability Standards : NISSAN：NDS01、FIAT/ALFA ROMEO 9.90110 、VOLKSWAGEN VW 801 01、GMW3172、HYUNDAI NO.ES 91500-00、FORD 00.00EA-D11-1 and on on，

– The Society of Automotive Engineers-SAE is for U.S.– The ISO 7637 & ISO16750 are for Europe – The Japanese of Automobile Organization-JASO is for Japan

2323

AEC - Standards AEC - Q100:

– Failure Mechanism Based Stress Test Qualification For Integrated Circuits

AEC - Q101: – Failure Mechanism Based Stress Test Qualification For Discrete

Semiconductors

AEC - Q200: – Stress Test Qualification For Passive Components

2424

QUALIFICATION TESTS Temperature & Humidity with DC Bias(H3TRB):

– 85℃, 85%rh, 5VDC, 1008hrs Precondition:

– 24hrs 150℃ soak, 168hrs 85℃/85%RH, 3 Reflows of peak temperature 260℃ Temperature Cycle:

– -55℃ to +150℃, 15minutes dwell, 1000 cycles High Temperature DC blocking:

– 150℃, 140V/70V, 1008hrs High Temp Storage (HTSL) :

– 150℃, no bias, 1008hrs Surge Ipp Test & ESD:

– 10/700 & 8/20– HBM >8KV

Others …

2525

Electrical Disturbances From Conduction & Coupling

5000 Pulses

5000 Pulses

1 hour

10 Pulses

Automotive 12V System

4. Enhance Electric Circuit Design In Protection For Raising Safety And ReliabilityA: EV Battery Sensing Line Protection

2727

Increased EV Battery Safety Requirements Sensing and Balancing Lines

FMVSS 305

Described:Retention of propulsion battery protection during a crash 

Added:Electrical isolation of the chassis from the high‐voltage system 

Protection for the signal line harness

ISO26262Functional safety for automotive electronics and electrical safety-related systems

OC/OV Protection

R filter

R Discharge

R filter

R Discharge

PassiveCell Balancing

Fuse

Fuse

Vp

Cd

Cm

Cm

Fuse

Cd

ASIL C or D Automotive Safety integrity level

2828

BMS “Decentralized Architecture” with High and Medium Voltage Fuses

IC Sense/Balancing

line “Slave”

Module N32

Vdc

to 1

25V

dc o

r hig

her

Module 1

CPU “Master”

Long wires interconnecting cells and slave board High likelihood to get short circuit under high voltage in case of crash

event inside module but also between modulesLittelfuse Solution Fuse in wire: 275A/251A Series Pico Fuse /477A Series Cartridge fuse SMD Fuse: 477A Series

Bat

tery

Pac

k Vo

ltage

~4V

2929

BMS “Centralized Architecture” with Low Voltage SMD Fuse

IC Sense/Balancing

Line “Slave”

Module N32

Vdc

to 6

3Vdc

Module 1

CPU “Master”

Short distance between cells and slave board Low likelihood to get short circuit under high voltage in case of crash

event. However, short circuit on slave board might occur inside the module due to component failure mechanism (capacitor, resistor … )

Littelfuse Solution SMD Fuse: 437A /440A Series

Bat

tery

Pac

k Vo

ltage

PCB

~4V

3030

Littelfuse Sensing Line Auto grade overcurrent protection based on AEC-Q200 standard

Series Technology Form Factor Package Breaking capacity

Voltage Rating

Current rating

437A440A

TFF 1206 SMD 50A 32Vdc –63Vdc

2A – 8A

477A Cartridge 5x 20 SMD 400A-1500A

400Vdc 2A-20A

477A Cartridge 5x20 Fuse in cable

400A –1500A

400Vdc 2A-20A

251 * Pico Fuse 7,11x 2,8mm Fuse in cable

300A 125Vdc 2A-10A

* AEC-Q200 pending for Pico 251 Series and released in March 2017 for 477A Series.

Suitable for Passive and Active Balancing

3131

Sensing and Balancing Lines Voltage rating vs. size and breaking capacity

Breaking Capacity Size

Voltage

1206

2,8 x 7,1mm in line leaded fuse

63Vdc

125Vdc

400Vdc 5x 20mm SMD

5x 20mm in line leaded fuse

437A/440A Series

Pico 251 Series *477A Series

50A 300A 500A 1500A

* AEC-Q200 pending for Pico 251 Series

Suitable for Passive and Active Balancing

4. Enhance Electric Circuit Design In Protection For Raising Safety And ReliabilityB: BMS Protection Devices Summary

33333333

Battery Management System and Protection Devices

440A/437A Series

251 Pico or 477A Cartridge Series

TPSMA6L/SD05

SM24CAN Series

TPSB Series

SPHV_C SeriesHC HEV fuses

3434

*Sense Line Fuses: *传感器线路保险丝：Sense Line Short Circuit Protection with electronic fuses can have very different requirements and not all fuses might be suitable. Littelfuse offers a variety of special tested electronic fuses for sense line applications. Please contact your Littelfuse sales or FAE for more details.使用电子保险丝进行传感器线路短路保护具有非常不同的要求，并非所有保险丝都能适合。力特为传感器线路应用提供各种各样经过测试的特殊的电子保险丝。欲知详情，请联系力特销售或现场应用工程师。

Littelfuse Protection Portfolio

437A 440A Series (SMD)

SP3030 Series

SP4021Series

SM24CAN Series

SPHV_C Series

0HEV Series

1

2

3

4 5Sense Line Fuse Options*传感器线路保险丝产品选择*

Cell Monitor IC Input OV Protection电池监测 IC 输入过电压保护

OV / ESD Protection for Daisy Chain I/F菊链 I/F 过电压/ESD 保护

OV / ESD Protectionfor CAN Bus I/F

CAN 总线 I/F 过电压/ESD 保护

High Voltage / Current Power Line Fuses高电压/电流电力线保险丝

6High Voltage TVS Transient Protection高电压 TVS 瞬变保护

SD05C Series

* 251 Pico Fuse Series (in line)

477A Series in line with harness or SMD

TPSMx Series

700Vdc/~250A

500Vdc/~125A

450Vdc/~40A- 275Vac/50A

ISO 8820 compliant

AEC-Q compliant* Pending

AEC-Q101compliant

Battery Management System and Protection Devices

L50QS

L70QS

3535

High Voltage Battery SystemLittelfuse Protection Portfolio – Selection Criteria

453 Serie

505 Series

• Voltage range depends on battery configuration, same for interrupt rating

• High temperature range >105oC

• Fuse should have a low temperature de-rating

• Low tolerance of cold resistance as well as long term stability is required

• Fuse should be able to cope with temperature cycles and vibrations

• Small Form factor for centralized architecture

• Ideally fulfills AEC-Q test conditions

• LF recommended: 440A Series, 437A Series, 477A Series, Pico 251 Series *)

• Package: SMD, in line, Radial leaded

• Voltage range depends on battery configuration

• Low leakage current • Power requirements

depend on transient environment and battery configuration

• LF offers 600W up to 3000W Diodes

• AEC-Q101 qualified

• Small form factor like TPSMA6L (Low Profile 600W Diode)

• LF recommended: TPSMA6L, TPSMB with stand off voltage range up to 550V

• Typical operating voltage of CAN Bus protectors is 24V

• Power rating between 200W to500W

• ESD Contact Capability of 30kV recommended

• Low capacitance between 11 to 30pF

• AEC-Q101 qualified

• Small Formfactor Packages SOD882 or SOT23-3 (2 channels)

• LF recommended: SM24CANA, SM24CANB, SPHV-C Series

• Operating voltage up to 1000VDC

• Low current fuse ratings 10A to 30A, 40A (420/450Vdc VDC)

• Medium current ratings 60A to 125A

• High current ratings 150A to 250A

• Form Factors 10x38, 42x20, 52x30

• High Interrupt Rating of 10kA

• Various mounting options: board mount, bolt down, blade, inline cable

• LF recommended: 0HEV/L50QS and L70QS Series (available) Medium / High Current Versions under development

• Following ISO8820-8 Requirements

• 5V Operating Voltage seems to be most common

• Low Capacitance is desirable

• Low leakage current

• Silicon Diode Arrays provide fastest protection and lowest clamp voltages

• Small Form factors of 0402 to 0603

• Power Capability several 10 to several 100W (8/20µs)

• AEC-Q101 qualified

• LF recommended: SP3030, SP4021

1 2

34

5Sense Line Fuse Cell Monitor IC Input OV Protection

OV / ESD Protection for Daisy Chain

OV / ESD Protectionfor CAN Bus I/F High Voltage / Current

Power Line Fuses6

High Voltage TVS Transient Protection

*Sense Line Fuses: *Sense Line Short Circuit Protection with electronic fuses can have very different requirements and not all fuses might be suitable. Littelfuse offers a variety of special tested electronic fuses for sense line applications. Please contact your Littelfuse sales or FAE for more details

4. Enhance Electric Circuit Design In Protection For Raising Safety And ReliabilityC: EV Chargers Protection

3737

EV Chargers and WW Standards

Charging StationUL 2594, GB/T 18487x, SAE J2293, IEC 61851.On Board Battery Charger

SAE J2894,IEC 61851,QC/T 895,GB/T 19751

On-/Off-Board Battery ChargerUL 2202

Charging inlet

IEC 62196UL 2251

SAE J1772Charging Plug

IEC 62196UL 2251

SAE J1772

Littelfuse experts provide guidance and support customers’ designs in accordance with worldwide automotive safety standards.

3838

EVSE to the Grid AC Charging (Slow charge) :

– Level 1: 120V, Single phase 2kW and below Typically takes 8-12 hours to charge fully depleted battery

– Level 2: 208-250V, Single phase (3,3kW ~20kW) Requires a 40A circuit; takes 4-6 hours typically to charge up fully depleted battery

– Level 3: 380V~440V, 3-phase (~20kW) Requires a 30A circuit; takes 4-6 hours typically to charge up fully depleted battery

DC Charging: (Quick charge) – INPUT: 480VAC, 3-phase– OUTPUT: 500VDC~1000VDC, 80A~250A, 100kW +– Typically provides 80% charge within 30 minutes

3939

On-Board vs. Off-Board Charger On-Board Charger Off-Board Charger

~20kW ~3,3kW ~7,7kW ~2kW ~100kW

Battery charge is managed by BMS Low power transfer Less concern on Battery thermal managementAdds weight to vehicleSlow charge

High power transfer More complex BMS to ensure battery thermal management Removes weight from vehicleFast charge

Power

+AC/AC

Charging StationAC/DC

ConverterAC/DC

Charging Station

4040

AC Charger Level – On-Board (Single-Phase)

Rectifier PFC DC/DC converterOC/OV OC/OV OC/OV

InputVoltage

PFCLink

OutputVoltage

EMIFilter

P

N

PE

Overvoltage:Varistor: AUMOV Series (AEC-Q200 March 2017), GDT: CG3 Series Overcurrent: 0HEV (ISO8820-1), 525A Series* * AEC-Q200 pending. Please contact your Littelfuse sales or FAE for more details.

120Vac/220Vac 500Vdc

AC

AC Cab

le

Stationarybase

In Vehicle

or

4141

On Board Charger System (OBC)Protection Needs - Details

1

2

AC Input Line(s) Fuses: Requires Automotive Grade Fuses for Over Current Protection that can conduct highcurrents (e.g. 16A, 32A) at voltages up to 250VAC single phase; high interrupt ratingand ability to withstand vibrations, surge transients and thermal cycles are key.

3

3

1

2

AC Input Line(s) Transient Protection: Due to the direct connection to the power grid transient (8/20µs) protection with MOVs andGDTs is required; the MOVs used need to work at elevated temperatures (125°C) andneed to offer AC line working voltages. AEC-Q200 approval is a must have.

AC

L

N

DC

4242

On Board Charger System (OBC)Protection Needs – Details 2

3 DC Link Capacitors and IGBT Over Voltage Protection

3.1

3.2

DC Link Capacitor Protection: Even though DC Link Capacitors are intended tofilter certain transients they still might need protection in certain cases; fast actingAuto Grade TVS Diodes can protect these costly parts

3.2

3.3

3.33.1

3.2 IGBT Gate Overvoltage Protection: IGBT Gate requires protection for Over Voltage Spikes; in former times Zener Diodes were used but these do not providethe same advantages as TVS Diodes like fast response, higher surge capability andbetter reliability.

3.3 IGBT Collector Emitter Inrush and Overvoltage Protection: Stacked TVS Diodes allow to protect the C-E high voltage side of IGBTs from harmful inrush andOver Voltage Transients

AC

L

N

DC

4343

On Board Charger System (OBC)Protection Needs – Details 3

4

5

High Voltage DC Link Over Current Protection: Helps to clear dangerous short circuit conditions that canbe caused due to faults in the OBC or Battery Pack or byexternal events like a car accident

6

DC / DC

Control Unit

Battery

CAN BUS

DC+

DC-

PE

4

4

5

5

6

High Voltage DC Link Over Voltage Protection: Clears overvoltage transients that can be introduced byswitching actions (hot plug) or that are introduced by othersystems of the car

CAN Bus – ESD and Transient Protection:The OBC communicates via CAN Bus with other systemslike the BMS. In the densely packed environment of a carCAN lines can be subjected to overvoltage stress causedby ESD (e.g. during assembly & maintenance) or othertransients introduced from other car systems via couplingor via conduction.

4444

AC Charger Level – On-Board (3 phase)

Rectifier PFC DC/DC converterOC/OV OC/OV

PFCLink

OutputVoltage

EMIFilter

N

PE

Overvoltage:Varistor: AUMOV Series (AEC-Q200 March 2017), GDT: CG3 Series Overcurrent: 0HEV (ISO8820-1), 525A Series* * AEC-Q200 pending. Please contact your Littelfuse sales or FAE for more details.

380Vac 500Vdc

AC

AC

Stationarybase

In Vehicle

OC/OV

Input Voltage

P3

Or

P2P1

Cab

le

4545

DC Charger – Off-Board (~ 100kW + / 3 Phases)Single 1x 100kW and modular structure 4x 25kW

Rectifier PFC DC/DC converterOC/OV OC/OV OC/OV

Input Voltage PFCLink

OutputVoltage

EMIFilter

P1

N

PE

Overvoltage:MOV: AUMOV Series (AEC-Q200 March 2017) and TMOV, GDT: CG3 Series Overcurrent: Charger with Monolithic structure: L50QS and L70QS SeriesCharger with Modular structure: 504 Series, 505 Series Please contact your Littelfuse sales or FAE for more details.

P2P3

Or

380Vac -480Vac 500Vdc700Vdc

4. Enhance Electric Circuit Design In Protection For Raising Safety And ReliabilityD: IGBT/MOSFET Protection

4747

DC/DC Converter Protection – Active Clamping

DC/DC converter

Overvoltage:TVS: TPSMx Series (AEC-Q101 qualified) Please contact your Littelfuse sales or FAE for more details.

500VdcPFC Link

IGBT/FET GateOvervoltage Protection

or

Single TVS or Stack of TVSs for IGBT active clamping voltage feature

IcVdc

Vclamp

Vce

Vdc

Vce

time

4848

IGBT/ MOSFET Driver Protection

Inpu

t Log

ic

PWM HS

GND

PWM LS

Vcc

Enable

µController

Vdd

HV DC link

Vdd

Vss

Input Logic: Diode Array SPx Series (AEC-Q101 qualified)Power Supply: MLA & AUML Series (AEC-Q200 qualified), TVS TPSMx Series (AEC-Q101 qualified) Gate Protection, Negative bias voltage: TVS TPSMx Series (AEC-Q101 qualified)

Cb

4949

High Voltage EV Charger Littelfuse Protection Portfolio

SP SeriesSM24CAN Series

TVS TPSMxx Series

0HEV Low Current

L50QSMedium Current *

L70QS High Current *

VaristorAUMOV Series TMOV Series*

MLV AUML Series

ESD

ISO 8820 compliant AEC-Q pending

L50HS Series

* Please contact your Littelfuse sales or FAE for more details.

On-Board Charger Off-Board Charger

* GDTCG3 Series

Overcurrent Protection Overvoltage Protection

On- and Off-Board Charger

525A Series *

AEC-Q101qualified

AEC-Q101 qualified AEC-Q200 (March 2017)

AEC-Q200 qualified

450Vdc/~40A- 275Vac/50A

500Vdc/~125A

700Vdc/~250A

450Vdc ~ 30A500Vac/420Vdc ~ 30A

500Vdc/Vac ~800AL70HS Series

700Vdc/Vac ~800A

504A Series

505A Series500Vac/500Vdc ~ 30A

Only Off-Board Charger

5050

Automotive Electronics Design Trends A. The market for vehicles using any kind of electric, battery-powered drive

system with voltages equal to or higher than 48V is expected to grow by double digits in the coming years.

B. Lithium-based battery technology will be the basis for any kind of xEV vehicles; in addition to its advantages of power density and charging cycle life, it requires major efforts in monitoring and protection.

C. Battery Management Systems in xEV vehicles are highly complex and mission-critical systems that need to be properly placed and selected protection components for overvoltage and short circuit protection.

5151

Littelfuse Services A. Electronic fuses for usage in vehicle systems like BMS Sense Line Protection need to

be selected carefully and should be able to pass reliability testing following the AEC-Q guidelines; consultation with fuse experts from Littelfuse is essential.

B. On-Board Charging Systems link closely with the BMS system of a vehicle and also require a high level of short circuit and overvoltage protection for AC and DC power systems, meeting automotive grade Reliability Expectations in terms of temperature, vibration and transient robustness. consultation with fuse experts from Littelfuse is essential.

C. Littelfuse provides guidance and support customers design according to worldwide automotive safety standards – Please contact your Littelfuse local expert!

52525252

5353

Global Footprint – R&D, Manufacturing & Support

Americas1. Chicago, Illinois, USA (S)2. Bellingham, Washington, USA (S)3. Boston, Massachusetts, USA (S, RD)4. Champaign, Illinois, USA (RD)5. Lake Mills, Wisconsin, USA (S, RD)6. Mount Prospect, Illinois, USA (RD)7. Rapid City, South Dakota, USA (S, RD, M)8. Fremont, California, USA (RD)9. Troy, Michigan, USA (S)10. Manaus, Brazil (S)11. São Paulo, Brazil (S)12. Saskatoon, Canada (S, RD, M)13. Matamoros, Mexico (M)14. Muzquiz, Mexico (M)15. Piedras Negras, Mexico (RD, M)

Europe16. Bremen, Germany (S, RD)17. Essen, Germany (S)18. Lauf, Germany (S)19. Legnago, Italy (RD, M)20. Ozegna, Italy (RD, M)21. Kaunas, Lithuania (RD, M)22. Amsterdam, Netherlands (S)23. Deventer, Netherlands (S)

Asia24. Beijing, China (S)25. Dongguan, China (RD, M)26. Hong Kong, China (S)27. Kunshan, China (S, M)28. Shanghai, China (S, RD, M)29. Suzhou, China (S, RD, M)30. Wuxi, China (RD, M)31. Tokyo, Japan (S)32. Tsukuba, Japan (RD, M)33. Seoul, Korea (S)34. Lipa City, Philippines (RD, M)35. Singapore (S)36. Chu-Pei, Taiwan (RD)37. Taipei, Taiwan (S)

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8

11

10

12

1513

14

16

17 18

20 19

21

22

24

2526

272829

30 3132

33

34

35

3637

S–International Sales RD–Research & DesignM–Manufacturing

23

The EndQ&A~~