Over the years, health and environmental issues surrounding air pollution and global climate change have forced government agencies to develop regulations to reduce pollutant emissions, especially for the automotive industry. Much progress has been made due to the introduction of cleaner fuels, catalytic converters, particle filters and more efficient engines. However, all of these advances are offset by increasing annual car sales, and government agencies need to impose more stringent restrictions, including fines, on automakers who do not meet the target of reducing emissions such as CO2. Figure 1 shows how passenger cars around the world continue to reduce their CO2 emissions over time and the government's goal of continuing to impose restrictions on a global scale.
Figure 1, CO2 emission reduction targets for passenger cars [1]
One way for automakers to reduce CO2 emissions from internal combustion engines and meet their goals is to automate the car, similar to electric trains: Hybrid electric vehicles combine an internal combustion engine with a 50 kW to 100 kW electric motor to accelerate or shut down the engine whenever possible. It can reduce CO2 emissions by 20% to 40%. Electric vehicles rely entirely on motors of 200 kW or higher and do not release any contaminants because they do not require an ICE for operation.
From the point of view of the high power required to operate the motor, the need to limit the current to a reasonable size and the need to maintain relatively light wiring, and the need to meet high voltage safety standards, EVs and HEVs require large, high-voltage batteries and require Completely redesign the electrical structure inside the car. Depending on the degree of electrification, such system costs can range from $4k to $10k. Unfortunately, for most people, this is too expensive and question whether the car will be widely sold in the market and can reduce the emissions of thousands of vehicles on the road.
In order to reduce costs, automakers are considering reducing the weight and size of their high-voltage systems, resulting in a large investment in research and development into smaller, more efficient, longer-lasting battery systems. This battery system uses a semiconductor material with less power loss, can operate at higher temperatures and produces less noise; this battery system uses a smaller package solution that introduces less spurious noise and can be operated during operation. Better dissipate the heat generated and withstand higher temperatures. By using smaller batteries, smaller and lighter cooling systems, and smaller noise filtering systems, the cost of EVs and HEVs should eventually be reduced, allowing EVs and HEVs to be widely marketed.
As an alternative to the current cost constraints of EVs and HEVs, European car manufacturers are developing a light hybrid car that relies on a 48 V grid. Selecting a battery voltage just below the high voltage safety threshold ensures that no rigorous and costly precautions are required to prevent high voltage safety hazards while still providing enough power to run a 10 kW to 20 kW belt starter motor. CO2 emissions can be reduced by 20% to 30% by providing basic functions such as start/stop and passive taxiing. In addition, the 48 V grid overcomes the power limitations of 12 V batteries and allows electrification of auxiliary functions such as pumps and turbochargers for better engine management. When achieving the same performance, the engine is able to reduce size and consume less fuel, which in turn reduces CO2 emissions. Finally, the 48 V grid also provides enough power to operate air-conditioning compressors and other types of pumps separately. In traditional cars, these are dragged by the engine through the belt, and if not charged, whenever the engine is used to save fuel ( Sliding, start/stop) will stop when it stops running.
The 48 V grid costs approximately $2.5k, and the ratio between CO2 emissions and fuel savings and cost increases is better than HEV or EV. In addition, it is no more expensive than the widely accepted diesel engines in the mass market and is therefore more promising to be widely accepted in the market. However, the cost of such vehicles will also increase, which is also an obstacle to be eliminated.
The challenge of further reducing the cost of 48 V systems is similar to that of EVs and HEVs: the need to continue to develop smaller, lighter, and more efficient systems can only be achieved with the support of the entire automotive supply chain, including the semiconductor industry.
Fairchild is fully committed to supporting CO2 emissions reductions and continues to interact with automotive manufacturers and system suppliers to develop and deliver the most advanced technologies in the automotive industry. Fairchild significantly improves silicon performance through its shielded gate MOSFETs, field-stop trench IGBTs and SuperFETs, covering medium voltage levels from 30 V to 100 V and high voltage levels from 600 V to 900 V. Improvements including packaging with silicon have become a limiting factor, and in this area, Fairchild once again leverages its expertise to provide advanced packaging solutions such as power modules, H-PSOF (TOLL), PQFN5x6, which have a small footprint. Allows higher currents to be driven with less electrical parasitics. By providing a large portfolio of components with higher power densities, Fairchild provides system designers with the flexibility to design scalable solutions and reduce their systems
The number of parallel components in the middle simplifies the board design, facilitates assembly and allows power semiconductors to be installed where it was previously impossible, and ultimately reduces the size and weight of the system for maximum reliability.
Needless to say, such a solution requires full compliance with automotive requirements for manufacturability, quality and reliability under severe operating conditions, which explains why only a few of the many possible solutions are successful in the market. .
Automotive electrification is growing faster and faster, and in a highly competitive environment, the time to market and the need to limit development costs have always been critical. Semiconductor companies have always been very conservative and cautious in adopting any new unverified new things. For them, supporting the automotive industry is really a challenge. Due to the fast-growing market, traditional trial and error methods are no longer accepted, and semiconductor companies must improve their modeling capabilities. Through a unique physical scalable model [2] and a packaged cross-coupling model, no matter how complex the underlying processes and physical principles are, [3] Fairchild allows designers to easily predict silicon performance in packages and optimize them for their precise needs. .
Last but not least, even in the automotive industry, supply chains, including semiconductor companies, are committed to environmental protection through better natural resource management, reduced waste, and active adoption of environmentally friendly materials in the assembly process. This demonstrates, for example, how power modules are developed using fully RoHS compliant green materials, which are lead-free solder-free and still meet the long-term reliability requirements of harsh operating conditions under the hood.
In short, cars have continued to reduce their CO2 emissions, but they have also been offset by the continued increase in cars on the road. Government departments have defined the stringent CO2 emission reduction targets that electric vehicles can achieve. Existing EV and HEV solutions have contributed to significant innovation, but as system costs remain high, large-scale expansions should be questionable. As an alternative, the 48 V stencil system currently offers better fuel and CO2 reductions compared to cost. In a fast-growing market, Fairchild offers the automotive industry the latest silicon technology and unique modeling capabilities with advanced packaging solutions, allowing automakers and system suppliers to optimize systems to reduce size and weight and save fuel. And ultimately reduce CO2 emissions.
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