Evolution of Hybrid Vehicle Electric System and it

APEC2007-SystemDesign28February2007–AnaheimEvolutionofHybridVehicleElectricSystemanditsSupportTechnologiesKimimoriHamadaTOYOTAMOTORCORPORATIONAPEC2007-SystemDesign28February2007–AnaheimContents1.ToyotaHybridSystem1.ToyotaHybridSystem--II(THSII(THS--II)II)2.ElectricComponentsinHybridsystem2.ElectricComponentsinHybridsystem3.3.HVInverterSimulationHVInverterSimulation4.IGBTdevelopment4.IGBTdevelopment5.Conclusion5.ConclusionAPEC2007-SystemDesign28February2007–Anaheim1.ToyotaHybridSystem1.ToyotaHybridSystem--IIII(THS(THS--II)II)APEC2007-SystemDesign28February2007–AnaheimToyotaHybridSystemIIToyotaHybridSystemIIPowersplitGeneratorBatteryMotorMechanicalpowerpathElectricalpowerpathHybridtransmissionEnginePowercontrolunitInverterBoostconverterdeviceAPEC2007-SystemDesign28February2007–AnaheimToyotaHybridSystemIIToyotaHybridSystemIIWithtwo-stagemotorspeedreductiondeviceMechanicalpowerpathElectricalpowerpathPowercontrolunitPowersplitdeviceGeneratorInverterBatteryMotorHybridtransmissionEngineBoostTwo-stagemotorspeedreductiondeviceSpeedTorqueOutputinhighgearpositionOutputinlowgearpositionconverterAPEC2007-SystemDesign28February2007–AnaheimMotorEfficiencyMotorEfficiencyHighefficiencyareaMotorspeedMotortorqueFixedmotorspeedreductiondeviceMotorspeedMotortorqueTwo-stagemotorspeedreductiondeviceAPEC2007-SystemDesign28February2007–AnaheimFuelEfficiency&FuelEfficiency&AccelerationPerformanceAccelerationPerformance20.022.525.027.530.032.535.02.533.544.5530-50mph(sec)USmodefuelefficiency(MPG)GS430GS350RX400hGToyota(2.4L)EBDAF(2.4L)CGoodGS450h（FR-HV)APEC2007-SystemDesign28February2007–Anaheim2.ElectricComponents2.ElectricComponentsinHybridSysteminHybridSystemAPEC2007-SystemDesign28February2007–AnaheimElectricCircuitsandEnergyFlowinTHSElectricCircuitsandEnergyFlowinTHS--IIIIFiltercapacitorMaincapacitorInductor288V650VPCU(powercontrolunit)BatteryBoostConverterInverterforgeneratorInverterformotorGeneratorMotor30kW50kW20kWAPEC2007-SystemDesign28February2007–AnaheimAPEC2007-SystemDesign28February2007–AnaheimAPEC2007-SystemDesign28February2007–AnaheimReactorWater-cooledheatsinkSmoothingcapacitorBoostpowermoduleMG-ECUConverterInverter&filtercapacitorInverterpowermoduleInternalStructureofPCUforGS450h-Coolingunits-Electric/electroniccircuits-Powersemiconductors-SimulationAPEC2007-SystemDesign28February2007–Anaheim3.HVInverterSimulation3.HVInverterSimulationAPEC2007-SystemDesign28February2007–AnaheimInverterMotorControllerTimeVehicleSpeedTimeTemperatureAcceleratorsignalAimsofSimulationTechnologyAimsofSimulationTechnologyBatteryINPUT-Chiptemperature-Currentbalance-Voltagesurge-Powerdissipationetc.OUTPUTAPEC2007-SystemDesign28February2007–AnaheimOverallStructureofHVInverterSimulationOverallStructureofHVInverterSimulationIGBTmoduleElectricalmodelElectricalmodelHeatsinkControlsystemThermalmodelThermalmodelSystemmodelSystemmodelMotorTemp.SmoothingcapacitorINVERTERAcceleratorsignalCurrentVoltageVoltageCurrentLossVehiclespecificationsCurrentFrequencyTorque(Weight,tire-diameter)Diagramofelectro-thermal-mechanicalsimulationforHVinvertersystemAPEC2007-SystemDesign28February2007–AnaheimE2VVP1GVVP1ERuLuRvLvRwLwVVN1EVWP1GVWP1EVWN1GVUP1GVUP1EVUN1GVWN1EVVN1GIGBT_WP1IGBT_WN1IGBT_VN1IGBT_VP1IGBT_UN1IGBT_UP1DWP1DWN1DVP1DVN1DUP1DUN1L1R1C1L2R2C2Lu2Lu3IGBT_WP2DWP2IGBT_WN2DWN2VWN2GVWN2EVWP2GVWP2EVUN1EDUN2DUP2DVN2DVP2IGBT_UN2IGBT_UP2IGBT_VN2IGBT_VP2VUP2GVUP2EVUN2GVUN2EVVN2GVVN2EVVP2GVVP2ELu9Lu4Lu10Lu5BusbarparasiticinductancematrixMotorCapacitorsDiodesIGBTsGatedrivecircuitsUVWElectricalmodelinHVinvertersystem(1)ElectricalmodelMajorPartsofInverterSimulationMajorPartsofInverterSimulationAPEC2007-SystemDesign28February2007–AnaheimIGBTpowerlossTemperatureofIGBTBottomofheatsinkThermalinterferencepartSilicon(IGBT)SolderCopper(DBC)AlN(DBC)Copper(DBC)SolderCopper(baseplate)GreaseAluminumalloy(heatsink)HeattransferDiodepowerlossTemperatureofdiode(2)ThermalmodelCompactthermalmodel(CTM)forIGBTmoduleincludingwater-coolingsystemAPEC2007-SystemDesign28February2007–AnaheimPredictionofIGBTtemperatureatfull-throttleacceleration025507510001234Time[s]Temperaturerise[degreeC]SimulationMeasurementVerificationofHVInverterSimulationVerificationofHVInverterSimulationAPEC2007-SystemDesign28February2007–Anaheim4.IGBTDevelopment4.IGBTDevelopmentAPEC2007-SystemDesign28February2007–AnaheimBatteryBoostconverterInverterGeneratorMotorHighHigh--VoltageElectricalSystemVoltageElectricalSystemPriusPrius500VDC200VDC650VDCRX400hRX400h288VDC970V1200VBuslinevoltageBatteryvoltageIGBTVBDAPEC2007-SystemDesign28February2007–AnaheimElectricfield(V/m）IncreaseofresistivityImprovementofIGBTBreakdownVoltageImprovementofIGBTBreakdownVoltageN-driftlayerN+P-VB=areaEcrit60080010001200140050100150200Thicknessofdriftlayer(um)Breakdownvoltage(V)50150250350450On-statelosses(W)dIncreaseofthicknessN+bufferlayer(A)(B)P+substrate●Increaseofon-statelossesaccompaniedwithimprovementinbreakdownvoltageGeneralwaystoimprovebreakdownvoltageofIGBTAPEC2007-SystemDesign28February2007–AnaheimIntroductionofIntroductionofEElectriclectri