Design and Measurement of Integrated Converters for Belt-Driven Starter-Generator in 48 V Micro/Mild Hybrid Vehicles

With reference to a 48 V belt-driven starter-generator used in micro/mild hybrid vehicles, this paper shows the design and measurement of an integrated H-bridge and of a compact dc/dc converter, both fabricated in low-cost high voltage-metal oxide semiconductor (HV-MOS) technology. The H-bridge is in charge of rotor excitation and, thanks to a direct copper bonding of the HV-MOS devices on a ceramic substrate, it ensures a full-integrated solution with low on-resistance values. The compact dc/dc converter interfaces the 48 V power domain with the lower voltage domain of sensing and control electronics, such as 5 and 1.65 V in this case study, without using cumbersome inductors and transformers. The latter are difficult to integrate into silicon technology. The converter has a multistage architecture where each stage implements a switched capacitor regulation. Multiple voltage outputs are supported with a configurable regulation factor sustaining an input voltage variation from 6 V (in case of cranking) up to 60 V. Specific design techniques have been implemented to reduce electromagnetic interference (EMI), typical of switching converters. Experimental measurements on fabricated prototype chipsets confirm the suitability of the presented designs for low-EMI 48 V applications.

[1]  Sergio Saponara,et al.  DC/DC converter integrated architecture for 48V supplies in micro/mild hybrid vehicle electrical engine control module , 2016, 2016 IEEE 16th International Conference on Environment and Electrical Engineering (EEEIC).

[2]  Michael Timmann,et al.  48V at Mercedes-Benz – options for further applications , 2014 .

[3]  I. Mukharjee,et al.  Simple, low EMI-noise input-filter design for DC/DC power regulators , 2012, 2012 7th IEEE Conference on Industrial Electronics and Applications (ICIEA).

[4]  Kye Yak See,et al.  Systematic Electromagnetic Interference Filter Design Based on Information From In-Circuit Impedance Measurements , 2010, IEEE Transactions on Electromagnetic Compatibility.

[5]  Vincent W Ng,et al.  High-efficiency, 12V-to-1.5V DC-DC converter realized with Switched-Capacitor architecture , 2009, 2009 Symposium on VLSI Circuits.

[6]  Zhe Chen,et al.  Dual-Electrical-Port Control of Cascaded Doubly-Fed Induction Machine for EV/HEV Applications , 2017, IEEE Transactions on Industry Applications.

[7]  V. Tarateeraseth.  Effect of extra CX on EMI filter performances , 2012, 2012 9th International Conference on Electrical Engineering/Electronics, Computer, Telecommunications and Information Technology.

[8]  J.-C. Le Bunetel,et al.  Impact of Periodic Switching Frequency Modulation control to reduce conducted EMI in Power Factor Converters , 2006, IECON 2006 - 32nd Annual Conference on IEEE Industrial Electronics.

[9]  Luca Fanucci,et al.  Improving electromagnetic compatibility of integrated switching converters for hybrid/electric vehicles , 2016, 2016 IEEE Electrical Power and Energy Conference (EPEC).

[10]  Chassard Pierre,et al.  Convertisseur DC-DC intégrable sur silicium avec isolation galvanique capacitive , 2015 .

[11]  Bruno Lequesne,et al.  Design and testing of a belt-driven induction starter-generator , 2001, IEMDC 2001. IEEE International Electric Machines and Drives Conference (Cat. No.01EX485).

[12]  Sanjaka G. Wirasingha,et al.  48-V Electrification: Belt-Driven Starter Generator Systems , 2014 .

[13]  K. Hirose,et al.  A novel digital soft-start circuit for dc-dc converter , 2011, 8th International Conference on Power Electronics - ECCE Asia.

[14]  Michiel Steyaert,et al.  CMOS Integrated Capacitive DC-DC Converters , 2012 .

[15]  Wu Xiaobo,et al.  On-Chip Soft-start Cell for DC-DC Converter , .

[16]  T. Erlbacher,et al.  Post-trench processing of silicon deep trench capacitors for power electronic applications , 2016, 2016 28th International Symposium on Power Semiconductor Devices and ICs (ISPSD).

[17]  Mohamed Bounadja,et al.  A high performance svm-dtc scheme for induction machine as integrated starter generator in hybrid electric vehicles , 2010 .

[18]  Gianpaolo Vitale,et al.  Design and performance evaluation of a high power density EMI filter for PWM inverter-fed induction motor drives , 2015, 2015 IEEE 15th International Conference on Environment and Electrical Engineering (EEEIC).

[19]  Yingqi Zhang,et al.  A new soft switching technique for buck, boost and buck-boost converters , 2002 .

[20]  A. Orlandi,et al.  EMI reduction in switched power converters using frequency Modulation techniques , 2005, IEEE Transactions on Electromagnetic Compatibility.

[21]  Peter J. Savagian,et al.  Induction Machine Design and Analysis for General Motors e-Assist Electrification Technology , 2015, IEEE Transactions on Industry Applications.

[22]  D. Sadarnac,et al.  Input Filter Damping Design for Control Loop Stability of DC-DC Converters , 2007, 2007 IEEE International Symposium on Industrial Electronics.

[23]  M.C. Di Piazza,et al.  A soft start technique to minimize EMI implications in dual voltage vehicle electrical system , 2002, IEEE 2002 28th Annual Conference of the Industrial Electronics Society. IECON 02.

[24]  Michael Evzelman,et al.  Average modeling technique for switched capacitor converters including large signal dynamics and small signal responses , 2011, 2011 IEEE International Conference on Microwaves, Communications, Antennas and Electronic Systems (COMCAS 2011).

[25]  Giuseppe Pinto,et al.  Simple Success With Conducted EMI From DC-DC Converters , 2012 .

[26]  N. Frohleke,et al.  Comparison of low voltage topologies for voltage regulator modules , 2002, Conference Record of the 2002 IEEE Industry Applications Conference. 37th IAS Annual Meeting (Cat. No.02CH37344).

[27]  Luca Fanucci,et al.  HV-CMOS Design and Characterization of a Smart Rotor Coil Driver for Automotive Alternators , 2013, IEEE Transactions on Industrial Electronics.

[28]  Andrea Cavagnino,et al.  Experimental Characterization of a Belt-Driven Multiphase Induction Machine for 48-V Automotive Applications: Losses and Temperatures Assessments , 2016, IEEE Transactions on Industry Applications.

[29]  Michael D. Seeman,et al.  Analysis and Optimization of Switched-Capacitor DC–DC Converters , 2008 .

[30]  Xiaocheng Jing,et al.  Soft-start circuit with duty ratio controlled voltage clamping and adaptive sizing technique for integrated DC-DC converters , 2010, 2010 IEEE International Conference of Electron Devices and Solid-State Circuits (EDSSC).

[31]  Shuangxia Niu,et al.  A Permanent-magnet double-stator integrated-starter-generator for hybrid electric vehicles , 2008, 2008 IEEE Vehicle Power and Propulsion Conference.

[32]  D. Richard,et al.  Valeo StARS Technology: A Competitive Solution for Hybridization , 2007, 2007 Power Conversion Conference - Nagoya.