Automotive design challenges for wide-band-gap devices used in high temperature capable, scalable power vehicle electronics

Abstract

Magna Electronics, an automotive Tier 1 Supplier, has been actively involved in the application and production of EV and Hybrid electric drive motors, inverters, electronic, and powertrain controllers. The Ford Focus Electric vehicle program includes all of these products and stand-alone inverters for the Fisker Karma, plus assorted components for other global customers. Incorporating advanced technologies into automotive power electronics remains in the forefront for next generation inverters. Smart product development will satisfy an emerging market for achieving high power density, high temperature capability, and high efficiency inverters with Wide Band Gap (WBG) devices utilizing both GaN and SiC in diodes and switches. It is essential that designs for motor power inverters, DC/DC converters, and in-vehicle chargers be based on a modular, scalable platform that will address the needs of electric and hybrid electric vehicles across a wide range of power requirements. The designs must meet objectives which are not new but need restating: Achieve lower cost targets (lower component and system costs); Develop new component technologies to meet high temperature and high power density requirements (WBG devices, electronics, bulk capacitor); Design of components and system architecture to meet scalability goals; Improve manufacturability of sub-system components These system design challenges will trickle down to component suppliers and, in particular the WBG community. Exposure to these attributes early in the component development process will speed up innovative automotive product development.