Automotive Traction Inverters: Current Status and Future Trends

Traction inverters are crucial components of modern electrified automotive powertrains. Advances in power electronics have enabled lower cost inverters with high reliability, efficiency, and power density, suitable for mass market consumer automotive applications. This paper presents an independent review of the state-of-the-art traction inverter designs from several production vehicles across multiple manufacturers. Future trends in inverter design are identified based on industry examples and academic research. Wide bandgap devices and trends in device packaging are discussed along with active gate driver implementations, current and future trends in system integration, and advanced manufacturing techniques.

[1]  Hector Sarnago,et al.  Heat Management in Power Converters: From State of the Art to Future Ultrahigh Efficiency Systems , 2016, IEEE Transactions on Power Electronics.

[2]  Kimimori Hamada,et al.  Present Status and Future Prospects for Electronics in EVs/HEVs and Expectations for Wide Bandgap Semiconductor Devices , 2008 .

[3]  Zhaohui Luo,et al.  A thermal model for insulated gate bipolar transistor module , 2004, IEEE Transactions on Power Electronics.

[4]  Ken Asakura,et al.  Development of Power Control Unit for Compact-Class Vehicle , 2009 .

[5]  Johann W. Kolar,et al.  Comparative Evaluation of Advanced Three-Phase Three-Level Inverter/Converter Topologies Against Two-Level Systems , 2013, IEEE Transactions on Industrial Electronics.

[6]  Brij N. Singh,et al.  Novel and ruggedized power electronics for off-highway vehicles , 2009, 2009 IEEE Vehicle Power and Propulsion Conference.

[7]  Ali Emadi,et al.  DC-Link Current and Voltage Ripple Analysis Considering Antiparallel Diode Reverse Recovery in Voltage Source Inverters , 2018, IEEE Transactions on Power Electronics.

[8]  New Possibilities with 800-Volt Charging , 2019 .

[9]  J.W. Kolar,et al.  Active Gate Control for Current Balancing of Parallel-Connected IGBT Modules in Solid-State Modulators , 2007, IEEE Transactions on Plasma Science.

[10]  Joachim Holtz,et al.  On continuous control of PWM inverters in the overmodulation range including the six-step mode , 1992, Proceedings of the 1992 International Conference on Industrial Electronics, Control, Instrumentation, and Automation.

[11]  Frede Blaabjerg,et al.  Complete Loss and Thermal Model of Power Semiconductors Including Device Rating Information , 2015, IEEE Transactions on Power Electronics.

[12]  Dragan Maksimović,et al.  High efficiency SiC traction inverter for electric vehicle applications , 2018, 2018 IEEE Applied Power Electronics Conference and Exposition (APEC).

[13]  Naoki Sakurai,et al.  Gate driver integrated circuit for high-current and high-speed insulated-gate bipolar transistors used in hybrid electric vehicle and electric vehicle inverters , 2017, 2017 IEEE 3rd International Future Energy Electronics Conference and ECCE Asia (IFEEC 2017 - ECCE Asia).

[14]  F.Z. Peng,et al.  Comparison of Traditional Inverters and $Z$ -Source Inverter for Fuel Cell Vehicles , 2004, IEEE Transactions on Power Electronics.

[15]  Toshifumi Yamakawa,et al.  Verification of Fuel Efficiency Improvement by Application of Highly Effective Silicon Carbide Power Semiconductor to HV Inverter , 2016 .

[16]  Kaname Sasaki,et al.  High-power-density Inverter Technology for Hybrid and Electric Vehicle Applications , 2014 .

[17]  Ye Li,et al.  Integrated Modular Motor Drive Design With GaN Power FETs , 2015, IEEE Transactions on Industry Applications.

[18]  Mohammad N. Anwar,et al.  Power Dense and Robust Traction Power Inverter for the Second-Generation Chevrolet Volt Extended-Range EV , 2015 .

[19]  Chen Wan-jun,et al.  Wide Bandgap Semiconductors for Power Electronics , 2021 .

[20]  J. Kolar,et al.  Closed-Loop di/dt and dv/dt IGBT Gate Driver , 2015 .

[21]  Cindy M Barnes,et al.  Practical Considerations Relating to Immersion Cooling of Power Electronics in Traction Systems , 2010, IEEE Transactions on Power Electronics.

[22]  Pavel Vaclavek,et al.  Disc inverter in highly integrated 9-phase drivetrain for E-mobility , 2015, 2015 17th European Conference on Power Electronics and Applications (EPE'15 ECCE-Europe).

[23]  Komei Hayashi,et al.  Development of compact power control unit for HEVs , 2017, 2017 IEEE Energy Conversion Congress and Exposition (ECCE).

[24]  Mohammad Anwar,et al.  Compact and high power inverter for the Cadillac CT6 rear wheel drive PHEV , 2016, 2016 IEEE Energy Conversion Congress and Exposition (ECCE).

[25]  S. Bernet,et al.  A comparison of three-level converters versus two-level converters for low-voltage drives, traction, and utility applications , 2005, IEEE Transactions on Industry Applications.

[26]  Thomas M. Jahns,et al.  The past, present, and future of power electronics integration technology in motor drives , 2017 .

[27]  Txomin Nieva,et al.  Gate driver for high power SiC modules: design considerations, development and experimental validation , 2017 .

[28]  Muhammed Rasit Atelge.  Power Module Packaging in Automotive Applications , 2016 .

[29]  Daniel Sadarnac,et al.  A review of on-board integrated chargers for electric vehicles , 2014, 2014 16th European Conference on Power Electronics and Applications.

[30]  John R. Fraley,et al.  A Compact 250 kW Silicon Carbide MOSFET based Three-Level Traction Inverter for Heavy Equipment Applications , 2018, 2018 IEEE Transportation Electrification Conference and Expo (ITEC).

[31]  M A Vogelsberger,et al.  Life-Cycle Monitoring and Voltage-Managing Unit for DC-Link Electrolytic Capacitors in PWM Converters , 2011, IEEE Transactions on Power Electronics.

[32]  Yasushi Yamada,et al.  Reliability of wire-bonding and solder joint for high temperature operation of power semiconductor device , 2007, Microelectron. Reliab..

[33]  Makoto Abe,et al.  Development of High Response Motor and Inverter System for the Nissan LEAF Electric Vehicle , 2011 .

[34]  Mohammad Pichan,et al.  Performance analysis of reduced common-mode voltage space vector modulation techniques for three-phase four-leg voltage-source inverter , 2018, 2018 9th Annual Power Electronics, Drives Systems and Technologies Conference (PEDSTC).

[35]  Sreekant Narumanchi,et al.  Evaluation of performance and opportunities for improvements in automotive power electronics systems , 2016, 2016 15th IEEE Intersociety Conference on Thermal and Thermomechanical Phenomena in Electronic Systems (ITherm).

[36]  Philippe Godignon,et al.  A Survey of Wide Bandgap Power Semiconductor Devices , 2014, IEEE Transactions on Power Electronics.

[37]  Jean-Marc Cyr.  Optimisation of IGBTs During the Commutation Process , 2015 .

[38]  Jason Zhang,et al.  Half-Bridge GaN Power ICs: Performance and Application , 2017, IEEE Power Electronics Magazine.

[39]  Weidong Xiao,et al.  Analysis and Evaluation of DC-Link Capacitors for High-Power-Density Electric Vehicle Drive Systems , 2012, IEEE Transactions on Vehicular Technology.

[40]  Y. Burkhardt,et al.  Design and analysis of a highly integrated 9-phase drivetrain for EV applications , 2014, 2014 International Conference on Electrical Machines (ICEM).

[41]  M. Alakula,et al.  Introducing a silicon carbide inverter for hybrid electric vehicles , 2008, 2008 IEEE Power Electronics Specialists Conference.

[42]  Ali Emadi,et al.  Advanced electric drive vehicles , 2014 .

[43]  Apostolos Dollas,et al.  Development of an FPGA-Based SPWM Generator for High Switching Frequency DC/AC Inverters , 2014, IEEE Transactions on Power Electronics.

[44]  Mahesh Krishnamurthy,et al.  A comprehensive evaluation of SiC devices in traction applications , 2014, 2014 IEEE Transportation Electrification Conference and Expo (ITEC).

[45]  Shaahin Filizadeh,et al.  An Optimized Space Vector Modulation Sequence for Improved Harmonic Performance , 2009, IEEE Transactions on Industrial Electronics.

[46]  Angelo Raciti,et al.  Generalized PWM–VSI Control Algorithm Based on a Universal Duty-Cycle Expression: Theoretical Analysis, Simulation Results, and Experimental Validations , 2007, IEEE Transactions on Industrial Electronics.

[47]  Lihua Chen,et al.  A low cost gate driver with dynamic turn-off transient control for HEV/EV traction inverter application , 2017, 2017 IEEE Applied Power Electronics Conference and Exposition (APEC).

[48]  Mehrdad Teimor,et al.  Development of a power dense and environmentally robust traction power inverter for the second-generatio chevrolet VOLT extended-range EV , 2015, 2015 IEEE Energy Conversion Congress and Exposition (ECCE).

[49]  Michael Brubaker,et al.  Understanding the contribution of switch input connection geometry to overall DC link inductance , 2015, 2015 17th European Conference on Power Electronics and Applications (EPE'15 ECCE-Europe).

[50]  B. Ozpineci,et al.  A 55 kW three-phase inverter with Si IGBTs and SiC Schottky diodes , 2006, Twenty-First Annual IEEE Applied Power Electronics Conference and Exposition, 2006. APEC '06..

[51]  Khwaja Rahman,et al.  Electrical Propulsion System Design of Chevrolet Bolt Battery Electric Vehicle , 2019, IEEE Transactions on Industry Applications.

[52]  Fang Zheng Peng,et al.  Application of Z-Source Inverter for Traction Drive of Fuel Cell—Battery Hybrid Electric Vehicles , 2007, IEEE Transactions on Power Electronics.

[53]  Ali Emadi,et al.  Analysis and design of a high efficiency, high power density three-phase silicon carbide inverter , 2016, 2016 IEEE Transportation Electrification Conference and Expo (ITEC).

[54]  Takaji Kikuchi,et al.  Development of Power Control Unit for Compact-Class Vehicle , 2016 .

[55]  Ali Emadi,et al.  Making the Case for Electrified Transportation , 2015, IEEE Transactions on Transportation Electrification.

[56]  A. Emadi,et al.  Traction inverters in hybrid electric vehicles , 2012, 2012 IEEE Transportation Electrification Conference and Expo (ITEC).

[57]  T.M. Jahns,et al.  Power Converter Design for an Integrated Modular Motor Drive , 2007, 2007 IEEE Industry Applications Annual Meeting.

[58]  Marco Liserre,et al.  H8 architecture for reduced common-mode voltage three-phase PV converters with silicon and SiC power switches , 2017, IECON 2017 - 43rd Annual Conference of the IEEE Industrial Electronics Society.

[59]  Nadir Idir,et al.  Active gate voltage control of turn-on di/dt and turn-off dv/dt in insulated gate transistors , 2006, IEEE Transactions on Power Electronics.

[60]  Fang Zheng Peng,et al.  Multilevel inverters: a survey of topologies, controls, and applications , 2002, IEEE Trans. Ind. Electron..

[61]  Sujit Das.  Life cycle assessment of carbon fiber-reinforced polymer composites , 2011 .

[62]  Kaushik Rajashekara,et al.  Present Status and Future Trends in Electric Vehicle Propulsion Technologies , 2013, IEEE Journal of Emerging and Selected Topics in Power Electronics.

[63]  Hans-Peter Nee,et al.  High-Efficiency 312-kVA Three-Phase Inverter Using Parallel Connection of Silicon Carbide MOSFET Power Modules , 2015, IEEE Transactions on Industry Applications.

[64]  Antonello Monti,et al.  Integrated circuit implementation for a GaN HFETs driver circuit , 2008 .

[65]  Gui-Jia Su,et al.  High-performance permanent magnet machine drive for electric vehicle applications using a current source inverter , 2008, 2008 34th Annual Conference of IEEE Industrial Electronics.

[66]  J. Chen,et al.  Design trends in smart gate driver ICs for power MOSFETs and IGBTs , 2017, 2017 IEEE 12th International Conference on ASIC (ASICON).

[67]  Mounira Berkani,et al.  Ageing and Failure Modes of IGBT Modules in High-Temperature Power Cycling , 2011, IEEE Transactions on Industrial Electronics.

[68]  Madhu Chinthavali,et al.  Optimized DC Link for Next Generation Power Modules , 2016 .

[69]  Hamid A. Toliyat,et al.  Applications of Wide Bandgap (WBG) devices in AC electric drives: A technology status review , 2017, 2017 IEEE International Electric Machines and Drives Conference (IEMDC).

[70]  J. W. Kolar,et al.  Design and Implementation of a Highly Efficient Three-Level T-Type Converter for Low-Voltage Applications , 2013, IEEE Transactions on Power Electronics.

[71]  Robert D. Lorenz,et al.  Sensing IGBT junction temperature using gate drive output transient properties , 2015, 2015 IEEE Applied Power Electronics Conference and Exposition (APEC).

[72]  Muhammad Pervaiz,et al.  Emerging Trends in Automotive Lightweighting through Novel Composite Materials , 2016 .

[73]  루도 세르쥬,et al.  Fast charging device for an electric vehicle , 2010 .

[74]  Yosuke Osanai,et al.  IGBT Gate Control Methods to Reduce Electrical Power Losses of Hybrid Vehicles , 2016 .

[75]  Leon M. Tolbert,et al.  Impact of SiC Devices on Hybrid Electric and Plug-In Hybrid Electric Vehicles , 2008, IEEE Transactions on Industry Applications.

[76]  Sinisa Jurkovic,et al.  Next generation chevy volt electric machines; design, optimization and control for performance and rare-earth mitigation , 2015, 2015 IEEE Energy Conversion Congress and Exposition (ECCE).

[77]  Sujit Das,et al.  Wide bandgap semiconductor opportunities in power electronics , 2016, 2016 IEEE 4th Workshop on Wide Bandgap Power Devices and Applications (WiPDA).

[78]  Eduardo P. Wiechmann,et al.  On the Efficiency of Voltage Source and Current Source Inverters for High-Power Drives , 2008, IEEE Transactions on Industrial Electronics.

[79]  Fang Zheng Peng.  Z-source inverter , 2002 .

[80]  Zhigang Liu,et al.  An Efficient DSP–FPGA-Based Implementation of Hybrid PWM for Electric Rail Traction Induction Motor Control , 2018, IEEE Transactions on Power Electronics.

[81]  Bulent Sarlioglu,et al.  Adoption of wide bandgap technology in hybrid/electric vehicles-opportunities and challenges , 2017, 2017 IEEE Transportation Electrification Conference and Expo (ITEC).

[82]  Geza Joos,et al.  A Dual Three-Level T-NPC Inverter for High-Power Traction Applications , 2016, IEEE Journal of Emerging and Selected Topics in Power Electronics.

[83]  Ali Emadi,et al.  A Fast Electro-Thermal Model of Traction Inverters for Electrified Vehicles , 2017, IEEE Transactions on Power Electronics.

[84]  F.Z. Peng.  Z-source inverter for motor drives , 2004, 2004 IEEE 35th Annual Power Electronics Specialists Conference (IEEE Cat. No.04CH37551).

[85]  Zhenxian Liang.  Status and trend of automotive power packaging , 2012, 2012 24th International Symposium on Power Semiconductor Devices and ICs.

[86]  Emil Levi,et al.  An EV Drive-Train With Integrated Fast Charging Capability , 2016, IEEE Transactions on Power Electronics.

[87]  Mitchell Olszewski,et al.  Oak Ridge National Laboratory Annual Progress Report for the Power Electronics and Electric Machinery Program , 2011 .

[88]  Hiroyuki Masumoto,et al.  A New IGBT Module with Insulated Metal Baseplate(IMB) and 7th Generation Chips , 2015 .

[89]  Guoyou Liu,et al.  Thermal design of a dual sided cooled power semiconductor module for hybrid and electric vehicles , 2017, 2017 IEEE Applied Power Electronics Conference and Exposition (APEC).

[90]  Thomas A. Lipo,et al.  Pulse Width Modulation for Power Converters: Principles and Practice , 2003 .

[91]  Ke Ma,et al.  A Lumped Thermal Model Including Thermal Coupling and Thermal Boundary Conditions for High-Power IGBT Modules , 2018, IEEE Transactions on Power Electronics.

[92]  Jurgen Steger.  A new generation of power modules with sinter-technology for the automotive industry , 2011, 2011 1st International Electric Drives Production Conference.

[93]  Jun Kikuchi,et al.  Performance and cost considerations for SiC-based HEV traction inverter systems , 2015, 2015 IEEE 3rd Workshop on Wide Bandgap Power Devices and Applications (WiPDA).

[94]  Takeshi Tokuyama,et al.  A novel direct water and Double-Sided Cooled Power Module for HEV/EV inverter , 2014, 2014 International Conference on Electronics Packaging (ICEP).

[95]  Michael Brubaker,et al.  Integrated DC link capacitor/bus enables a 20% increase in inverter efficiency , 2014 .

[96]  Alan G. Holmes,et al.  The GM RWD PHEV Propulsion System for the Cadillac CT6 Luxury Sedan , 2016 .

[97]  Ali Emadi,et al.  Bus Bar Design for High-Power Inverters , 2018, IEEE Transactions on Power Electronics.

[98]  Yong Kang,et al.  Analysis and Calculation of DC-Link Current and Voltage Ripples for Three-Phase Inverter With Unbalanced Load , 2015, IEEE Transactions on Power Electronics.

[99]  José R. Rodríguez,et al.  A Survey on Neutral-Point-Clamped Inverters , 2010, IEEE Transactions on Industrial Electronics.

[100]  Leif Amber,et al.  Hybrid Si IGBT-SiC Schottky diode modules for medium to high power applications , 2017, 2017 IEEE Applied Power Electronics Conference and Exposition (APEC).

[101]  R. Tummala,et al.  Review of Thermal Packaging Technologies for Automotive Power Electronics for Traction Purposes , 2018 .

[102]  H. van der Broeck,et al.  Analysis and Realization of a Pulse Width Modulator Based on Voltage Space Vectors , 1986, 1986 Annual Meeting Industry Applications Society.

[103]  Ali Emadi,et al.  A Review of Shaft Voltages and Bearing Currents in EV and HEV Motors , 2016, IECON 2016 - 42nd Annual Conference of the IEEE Industrial Electronics Society.