3.1 (Version 1.1)

APEC 2007 - System Design
28 February 2007 Anaheim

Evolution of Hybrid Vehicle
Electric System and its Support
Technologies
Kimimori Hamada
TOYOTA MOTOR
CORPORATION
Contents
1. Toyota Hybrid System
-
-
II (THS
II (THS
-
-
II)
II)
2. Electric Components in Hybrid system
2. Electric Components in Hybrid system
3.
3.
HV Inverter Simulation
HV Inverter Simulation
4. IGBT development
4. IGBT development
5. Conclusion
5. Conclusion
-
-
II
II
(THS
(THS
-
-
II)
II)
Toyota Hybrid System II
Power split
Generator
Battery
Motor
Mechanical power path
Electrical power path
Hybrid
transmission
Engine
Power control unit
Inverter
Boost
converter
device
With two-stage motor speed reduction device
Mechanical power path
Electrical power path
Power control unit
Power split device
Generator
Inverter
Battery
Motor
Hybrid transmission
Engine
Boost
Two-stage motor
speed reduction device
Speed
T
o
r
q
u
e
Output in high
gear position
Output in low gear
position
converter
Motor Efficiency
Motor Efficiency
High
efficiency area
Motor speed
M
o
t
o
r

t
o
r
q
u
e
Fixed motor speed
reduction device
Motor speed
M
o
t
o
r

t
o
r
q
u
e
Two-stage motor speed
reduction device
Fuel Efficiency &
Fuel Efficiency &
Acceleration Performance
Acceleration Performance
20.0
22.5
25.0
27.5
30.0
32.5
35.0
2.5 3 3.5 4 4.5 5
30-50 mph (sec)
U
S

m
o
d
e

f
u
e
l

e
f
f
i
c
i
e
n
c
y

(
M
P
G
)
GS430
GS350
RX400h
G
Toyota
(2.4L)
E
B
D
A
F
(2.4L)
C
G
o
o
d
GS450h
FR-HV)
2. Electric Components
2. Electric Components
in Hybrid System
in Hybrid System
Electric Circuits and Energy Flow in THS
Electric Circuits and Energy Flow in THS
-
-
II
II
Filter
capacitor
Main
capacitor
Inductor
288V
650V
PCU (power control unit)
Battery
Boost Converter
Inverter
for generator
Inverter
for motor
Generator
Motor
30kW
50kW
20kW
Reactor
Water-cooled heat sink
Smoothing capacitor
Boost power module
MG-ECU
Converter
Inverter
& filter capacitor
Inverter power module
Internal Structure of PCU for GS450h
- Cooling units
- Electric/electronic circuits
- Power semiconductors
- Simulation
3. HV Inverter Simulation
3. HV Inverter Simulation
Inverter
Motor
Controller
Time V
e
h
i
c
l
e

S
p
e
e
d
Time T
e
m
p
e
r
a
t
u
r
e
Accelerator
signal
Aims of Simulation Technology
Aims of Simulation Technology
Battery
INPUT
- Chip temperature
- Current balance
- Voltage surge
- Power dissipation
etc.
OUTPUT
Overall Structure of HV Inverter Simulation
Overall Structure of HV Inverter Simulation
IGBT module
Electrical model Electrical model
Heatsink
Control
system
Thermal model Thermal model
System model System model
Motor
Temp.
Smoothing capacitor
INVERTER
Accelerator
signal
Current
Voltage
Voltage
Current
Loss
Vehicle specifications
Current
Frequency
Torque
(Weight, tire-diameter)
Diagram of electro-thermal-mechanical simulation
for HV inverter system
E2
VVP1G
VVP1E
Ru Lu
Rv Lv
Rw
Lw
VVN1E
VWP1G
VWP1E
VWN1G
VUP1G
VUP1E
VUN1G
VWN1E
VVN1G
IGBT_WP1
IGBT_WN1 IGBT_VN1
IGBT_VP1
IGBT_UN1
IGBT_UP1
DWP1
DWN1
DVP1
DVN1
DUP1
DUN1
L1
R1
C1
L2
R2
C2
Lu2
Lu3
IGBT_WP2
DWP2
IGBT_WN2
DWN2
VWN2G
VWN2E
VWP2G
VWP2E
VUN1E
DUN2
DUP2
DVN2
DVP2
IGBT_UN2
IGBT_UP2
IGBT_VN2
IGBT_VP2
VUP2G
VUP2E
VUN2G
VUN2E
VVN2G
VVN2E
VVP2G
VVP2E
Lu9
Lu4
Lu10
Lu5
Busbar parasitic inductance matrix
Motor
Capacitors
Diodes
IGBTs
Gate drive
circuits
U
V
W
Electrical model in HV inverter system
(1) Electrical model
Major Parts of Inverter Simulation
Major Parts of Inverter Simulation
IGBT power loss
Temperature of
IGBT
Bottom of heatsink
Thermal
interference part
Silicon (IGBT)
Solder
Copper (DBC)
AlN (DBC)
Copper (DBC)
Solder
Copper (base plate)
Grease
Aluminum alloy
(heatsink)
Heat transfer
Diode power loss
Temperature of
diode
(2) Thermal model
Compact thermal model (CTM) for IGBT module
including water-cooling system
Prediction of IGBT temperature at full-throttle acceleration
0
25
50
75
100
0 1 2 3 4
Time [s]
T
e
m
p
e
r
a
t
u
r
e

r
i
s
e

[
d
e
g
r
e
e

C
]
Simulation
Measurement
Verification of HV Inverter Simulation
Verification of HV Inverter Simulation
4. IGBT Development
4. IGBT Development
Battery
Boost
converter
Inverter
Generator
Motor
High
High
-
-
Voltage Electrical System
Voltage Electrical System
Prius
Prius 500VDC 200VDC
650VDC
RX400h
RX400h 288VDC
970V
1200V
Bus line voltage Battery voltage
IGBT V
BD
Electric field (V/m
Increase of
resistivity
Improvement of IGBT Breakdown Voltage
Improvement of IGBT Breakdown Voltage
N
-
drift layer
N
+
P
-
VB
=area
Ecrit
600
800
1000
1200
1400
50 100 150 200
Thickness of drift layer (um)
B
r
e
a
k
d
o
w
n

v
o
l
t
a
g
e

(
V
)
50
150
250
350
450
O
n
-
s
t
a
t
e

l
o
s
s
e
s

(
W
)
d
Increase of thickness
N
+
buffer layer
(A)
(B)
P
+
substrate
Increase of on-state losses

accompanied with improvement
in breakdown voltage
General ways to improve
breakdown voltage of IGBT
Introduction of
Introduction of
E
E
lectric
lectric
F
F
ield
ield
D
D
ispersion (EFD) Layer
ispersion (EFD) Layer
Conventional
structure
(trench IGBT)
Conventional
structure
(trench IGBT)
Novel
structure
(EFD IGBT)
N
-
drift layer
N
+
P
-
N
+
buffer layer
P
+
substrate
N
-
drift layer
N
+
P
-
N
+
buffer layer
P
+
substrate
N
-
drift layer
N
+
P
-
N
+
buffer layer
P
+
substrate
EFD layer
Electric
field (V/m)
Electric field
dispersion
principal
(Low BV)
(High BV)
(High BV)
Design and Effect of EFD Layer
Design and Effect of EFD Layer
1180
1190
1200
1210
Doping concentration of
EFD layer (arb. unit)
B
r
e
a
k
d
o
w
n

v
o
l
t
a
g
e

(
V
)

Thinner
-10%
1000
1100
1200
1300
Without
EFD layer
B
r
e
a
k
d
o
w
n

v
o
l
t
a
g
e

(
V
)

230
250
270
290
O
n
-
s
t
a
t
e

l
o
s
s
e
s

(
W
)

With
EFD layer
Thicker
Effect of EFD layer Breakdown voltage dependence
on EFD layer conditions
Benchmark of Toyota In
Benchmark of Toyota In
-
-
House IGBTs
House IGBTs
180
220
260
300
340
500 750 1000 1250 1500
Breakdown voltage (V)
O
n
-
s
t
a
t
e

l
o
s
s
e
s

(
W
/
c
m
2
)
0
6

G
S
0
5

R
X
C
o
m
p
e
t
i
t
o
r
s
G
o
o
d
T
o
y
o
t
a
Evolution of In
Evolution of In
-
-
House IGBTs
House IGBTs
Chip appearance
Chip size (mm
2
)
Chip thickness (um)
Breakdown voltage (V)
On-state losses
(W/cm
2
)
Item 03 Prius 05 RX
13.7
9.7 12.75
9.39
380 375
970 1200
265 242
06 GS
300
232
12.75
9.39
1200
Device structure Planar IGBT EFD IGBT EFD IGBT
5. Conclusion
5. Conclusion
-
-
-
-
THS-II realizes dual requirements of fuel efficiency
and acceleration performance by employing boost
converter and two-stage motor speed reduction
device.
The electrical components of the THS-II are
contributing to making the system more compact,
and lightweight, and to increasing its power density.
An HV inverter simulation has been developed as a
powerful tool for HV system development.
Low loss high-breakdown voltage novel
IGBTs ,named EFD IGBTs, have been successfully
developed for the THS-II.
Thank you!
Thank you!

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APEC 2007 - System Design

28 February 2007 Anaheim

Increase of on-state losses

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