Freescale PowerPoint Template

August, 2010

Freescale Solutions for Powertrain and Hybrid AUT-F0553 Cherif Assad Powertrain and HEV Segment Marketing Manager TM

Freescale, the Freescale logo, AltiVec, C-5, CodeTEST, CodeWarrior, ColdFire, C-Ware, mobileGT, PowerQUICC, StarCore, and Symphony are trademarks of Freescale Semiconductor, Inc., Reg. U.S. Pat. & Tm. Off. BeeKit, BeeStack, CoreNet, the Energy Efficient Solutions logo, Flexis, MXC, Platform in a Package, Processor Expert, QorIQ, QUICC Engine, SMARTMOS, TurboLink and VortiQa are trademarks of Freescale Semiconductor, Inc. All other product or service names are the property of their respective owners. © 2010 Freescale Semiconductor, Inc.

Session Introduction ►This • • • •

session aims:

To provide markets trends in automotive electrification regarding the powertrain To address the emission reductions and standard regulations compliancy To outline to the audience the technical challenges To review Freescale solutions and how they can solve customer problems


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Session Objectives ►After • • • • • •

completing this session you will be able to:

Discuss the meaning of market trends Compare the range of applications Describe the high level electrical components Compare Freescale‘s range of products Identify the key players in the supply chain Participate actively in further technical session


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Agenda ►Powertrain

& Hybrid Markets Environment

►Semiconductor

►Freescale

►Battery

►Power

Technology Review

Controllers for Powertrain & Hybrid

Management Products

Electronics Bricks

►Session

Review and Wrap-up


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Powertrain & Hybrid Market Environment


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Combustion Engine and Hybrid Vehicle ► Regulations

are driving the industry innovation path ► Engine downsized for fuel consumption and efficiency ► Powertrain pulled by car electrification and affordable mobility in emerging markets

1-2 Cylinder

3-6 Cylinder

< 12 cylinder

1-2 Cylinder

Hybrid & Electrical Vehicle

S12(X)

S12(X)

BASELINE Freescale, the Freescale logo, AltiVec, C-5, CodeTEST, CodeWarrior, ColdFire, C-Ware, mobileGT, PowerQUICC, StarCore, and Symphony are trademarks of Freescale Semiconductor, Inc., Reg. U.S. Pat. & Tm. Off. BeeKit, BeeStack, CoreNet, the Energy Efficient Solutions logo, Flexis, MXC, Platform in a Package, Processor Expert, QorIQ, QUICC Engine, SMARTMOS, TurboLink and VortiQa are trademarks of Freescale Semiconductor, Inc. All other product or service names are the property of their respective owners. © 2010 Freescale Semiconductor, Inc.

GROWTH TM

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Automotive Semiconductor Demand (SAM) • $11.2 billion SAM (‘09), growing at 11.7% CAGR through 2015 ($21.2B TAM) Excludes memory, discretes, optoelectronics and sensors

Source: Strategy Analytics July 2010


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Powertrain Electrification Advanced ICE

Micro Hybrid

►In Cylinder combustion control (pressure)

►Start Stop system, belt driven or modified starter

►High pressure on Common Rail

►Electronic embedded system in the alternator

►Direct actuation ►Thorough Injector and ingnition control ►Air Charge and NOx trap

Hybrid / Electric ►High voltage battery ►Converter DC/DC ►Inverter module DC/AC ►Battery charger

►Oil/Water/Fuel Electric Pumps ►Low voltage Battery management ►HVAC compressor

►Smart grid

►On/Off cycle sustainable

Anciliaries

►Torque assistance ►Regenerative energy

Design Challenges •Combustion Control •Emission

Monitoring •Exhaust Gas Treatment

Energy Management High Power Efficiency Multi Core MCU


Software Enablement Functional Safety Packaging Integration

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Global Regulation Standards Summary

►

The new CAFE standards must achieve by 2016 a combined average fuel-economy standard of 35.5 mpg—39 mpg for cars and 30 mpg for light trucks and SUVs—a 40 percent improvement over current standards.

►

Japan‘ emissions standards in 2009 tightened further limits about NOx and PM to a level in-between the US 2010 and Euro 5 requirements.

►

Emission standards are being adopted in China by the State Environmental Protection Administration (SEPA). Chinese standards are based on European regulations. Focus investment area-HEV and Fuel Cell.

►

Europe emission concerns may provide short term an opportunity for low-priced start/stop gasoline-electric hybrid vehicles. Euro 6 standards effective from fall 2014, with a target to reach 95g CO2 by 2020.


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Future Architecture Challenges ► Lower

cost of ownership

•

Lower ASPs!!! • Reduced development costs • Faster time to market ► Power •

consumption

Customers requesting 50% reduction in power over existing architecture

► Performance •

Customers requesting up to 5x performance over existing architecture

► Functional

Safety

•

ASIL-C or ASIL-D compliance for most applications • LFET

+ Very high power product for automotive

85V/400A 20V/400A Micro-Hybrid Start & Stop

Micro-MildHybrid

Full-Hybrid Mild-Hybrid

Electric drive

Regenerative Braking


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Freescale Controllers for Powertrain & Hybrid


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Gasoline Engine Management Main Requirements

Gasoline Engine Management ECU

FEC

ADC SPI Timer

Power stage

Injectors

Ignition Driver

Power stage

Spark Plugs

Bridge Driver

Power stage

Throttle

Freescale Products

PWM DMA

Power Supply

FRay

CAN

PHY I/F CAN,LIN, Flexray,

Injector Drivers

32-bit MCU

LIN

CAN LIN FlexRay Diagnostic

RTC

Crank speed Cam position Clutch/brake Speed

Input Signal Conditioning Circuit

Throttle position Accelerator Air Mass Airflow Battery Temperatures Knock sensor Oxygen sensors Fuel Pressure

Increased fuel economy Reduced emissions (CO, Total hydrocarbons (HC), O3, and NOx particulates) Improve reliability Increase Performance Reduce Mechanical Content Increase Engine Efficiency

8/16 bit Safety MCU

Output Drivers

Relays Fuel pump Oxygen Heater Cam Control Recirculation Valves Idle Control

Power Supply


Microcontroller: MPC55xx family MPC563xM, MPC5674F Power Supply & interfaces: MC33730, MC339905 Integrated custom chipsets Switches: MC33800, MC33810, MC33812 Integrated custom chipsets CAN Interface: MC33902 HBridge: MC33899, MC33926, MC33931, MC33932 Pressure sensors: MPXHZ6115, MPXHZ6250

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Automatic Manual Transmission Transmission ECU

SBC Power Supply And Physical I/F

CAN/LIN

32-bit MCU

Switch Detection

Cranking Cranking relay Auto Switch Door switch

Input Signal Conditioning Circuit

Battery Voltage Brake Pedal Position Vehicle Speed Clutch Speed Clutch Position Gear Position Shift Position Hydraulic Pressure Gear Selection

Multiple Low-Side Switch & Driver

Power Supply

Optional Safety 8-bit MCU

Solenoid Monitor


Main power relay Pump relay Buzzer

Power Stage

Shift Valve

Power Stage

Shift Valve

Power Stage

Gear Valve

Power Stage

Gear Valve

Power Stage

Clutch Valve

Valves feedback

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Motorcycle Engine Management Main Requirements Lowest cost ECU PCB Size reduced for integration Injection Control to comply regulations Best fit system partitioning

Motorcycle Engine Management ECU

CAN

RTC

Diagnostic

8/16-bit MCU PWM

Sensor Supply Tachometer Lamps

LIN

Timer

Ignition switch Battery Crankshaft Sensor

ADC

SPI

Manifold Pressure Acceleration position Air Temperature Engine Temperature

supply Mixed Signal Application Specific Standard Product ASSP

Freescale Products

Idle control Fan Relay Fuel Pump Fuel Injector

Power stages

Spark Plug

Power Supply


Microcontroller: S12(X) family S12P Power Supply & interfaces: MC33904 or 905 PowerSBC05 or 10 Integrated custom chipsets Switches: MC33800, MC33810, MC33812 Integrated custom chipsets CAN Interface: MC33902 Pressure sensors: MPXHZ6115, MPXHZ6250

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BLDC / DC Pump Motor

SBC Power management: MC33742, MC33904/5 VBAT Power Supply

MCU:

1-3

Battery

BAT

Temperatures

8/16 bit MCU ADC

Battery monitoring MM912xxx

SPI I/O

M N MOS

CAN CAN/LIN BUS

LIN, CAN PHY/I: MC33661, MC33902

BLDC Motor

N MOS

H-BRIDGE

MC9S08AW, SG, MP16, MC9S12Q, MC9S12XS

Power MOSFET (NMOS)

H bridge driver:

Die – Consult Factory

MC33937A

VBAT

DC Motor Output Driver

M

Output driver low RdsOn: MC33981, MC33982


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HEV / EV – Where Freescale Plays HV Battery management S12(X), LV Battery management MM912xxx IDC, S12(X)

Battery

DC/DC converter S08, S12(X)

Generator

Engine control analog drivers, pressure sensor, S08, MOSFET

Power circuit

Power split device

Inverter

Engine

Inverter and motor control S12(X), Gate driver

Motor

µHybrid, S/Stop S08, S12(X), MOSFET

Charger MCU S08, S12(X)

Drive Wheels


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Legislation Drives MCU Powertrain

 32bit CPU  80 MIPs  36K SRAM  1M Flash

 32bit CPU  200 MIPS  64K SRAM  2M Flash

 ~1000 MIPs  384K SRAM  6M Flash  dual eTPU2

 600 MIPS  256K SRAM  4M Flash  dual eTPU

MPC5676, MPC564xL

MPC5674F

MPC5554

EURO III

EURO IV

MPC57xx

EURO VI CAFÉ

Euro V  Port fuel injection  Flexfuel

 ~1500 MIPs  512K SRAM  8M Flash  quad ATS  low power

 GDI  High pressure Common rail

 Combined engine & transmission

 Hybrid, car electrification  Valvetronic  HCCI

 16bit based injection systems

2000

2004

2006

2012

2009


2014 TM

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MPC57xx Device Proposal (Up to 200MHz) 200MHz PowerPC™ e200Z4d

SWT

FP

INTC

VLE

I-RAM 64K

4k I-Cache 2kCACHE D-Cache

SWT PowerPC™ e2004d STM SWT PowerPC™ INTC e200Z4d STM FP

STM

FPVLE

D-RAM 64K

INTC

VLE 8k I-Cache I-RAM 64K 4k4k I-Cache CACHE D-Cache D-RAM 64K 2kCACHE D-Cache

Debug JTAG Nexus

50-100 MHz SWT

STM

PowerPC™ e200Z4d

eDMA

DigRF

INTC

DSP Ethernet

I-RAM 64K

VLE FlexRay

D-RAM Security

Hi Bandwidth Cross Bar Switch (5x2) with ECC

Platform Cross Bar Switch (8x4) with ECC

Memory Protection Unit

Memory Protection Unit

P Flash

4M Flash

64k EEPROM

16k Overlay

AIPS Bridge A

Periph

SRAM Ctrl

Periph

►Permanent

Lock-step for Safety. ►Third main core for increased performance. Computational Shell at max Frequency ►I/O processor for Timed Non safety-related functions. ►Peripheral Domain at max 50MHz ►Total SRAM >320K bytes ►Current Target: < 350 mA Freescale, the Freescale logo, AltiVec, C-5, CodeTEST, CodeWarrior, ColdFire, C-Ware, mobileGT, PowerQUICC, StarCore, and Symphony are trademarks of Freescale Semiconductor, Inc., Reg. U.S. Pat. & Tm. Off. BeeKit, BeeStack, CoreNet, the Energy Efficient Solutions logo, Flexis, MXC, Platform in a Package, Processor Expert, QorIQ, QUICC Engine, SMARTMOS, TurboLink and VortiQa are trademarks of Freescale Semiconductor, Inc. All other product or service names are the property of their respective owners. © 2010 Freescale Semiconductor, Inc.

256k SRAM

AIPS Bridge B

Periph

Periph

Peripherals: Same as Low end except: ADC: 68 channels total 4xCAN 5xSCI 6xdSPI Security module Including: Secure CPU, flash & RAM AES 128 Encryption/Decryption True Random number generator Secure keys

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1MB - MPC5643L PMU SWT

PowerPC™ e200

MCM

FPU

STM

VLE

INTC

MMU

Debug JTAG Nexus

FlexRay

CACHE CACHE

eDMA

I/O Bridge

SWT

FPU

MCM

VLE

STM

MMU

INTC

CACHE CACHE

RC

Cross Bar Switch Memory Protection Unit

PowerPC™ e200

Core ► Up to 120MHz PowerPC ISA Dual e200 zen4 core ► 4K 2-way / 4-way I-cache ► FPU ► Safety enhanced Cores + FPU + VLE + MMU ► Dual Parallel or Lock Step configuration + HW/SW monitoring

PMU

Memory ► Up to 1MByte RWW Flash with ECC ► Up to 128 KByte SRAM with ECC ► EE emulation ► Dual crossbar with MPUs

eDMA

Cross Bar Switch Memory Protection Unit

RC

RC

1M FLASH (ECC)

128K SRAM (ECC)

I/O ► 2 x FlexCAN (32 message buffers each) ► 1 x FlexRay (64 msg. buffers) ► 2 x LINFlex ► 3 x DSPI ► 1 x External clock output ► 2 x FlexPWM (2 x 12 channels) ► 3 x eTimer modules (3 x 6 channels) ► Dual ADC (16 channels each, 12bit), 1 S/H per ADC ► 1 x Cross-triggering unit for motor control

I/O Bridge

2x ADC

CTU

2x FlexPWM

3x eTimer

2 FlexCAN

3 x DSPI

2x LINFlex

TSENS

FCCU

Communications I/O System

RC

System ► 16 Channels eDMA ► Autonomous Fault Collection and Control Unit ► CRC computing unit ► Software watchdog timer (inc. window mode, flow monitoring) ► 2 x Junction temperature sensor ► Nexus debug interface (up to N3) ► FM-PLL + FlexRay PLL ► 3.3 V Single supply with external and internal ballast transistor ► 3.3 V I/Os (ADC 5 V capable) ► 144 LQFP / 257 MAPBGA ► Tj = 150°C


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Start/Stop Application MCU: MC9S08SG

VBAT Power Supply

MC9S12XS

1-3

SCI ADC

System Basis Chip:

MC33742, MC33905

LIN, CAN PHY/I:

MCU

I/O

CAN / LIN I/O

MC33661, MC33902

3-Phase Gate Driver

MC9S12P

N MOS

Alternator/ Starter M

N MOS

CAN/LIN BUS

3-Phase Gate driver: MC33937A

►Multiple

MOSFET at higher frequency to control Motor in multiple phases configuration

Power MOSFET:

►―Sub-mW‖

Die – Consult Factory

►Reverse

devices , 0.6 mOhm at 550A

mode using body diode at 400A

►Repetitive

UIS : 60M cycles at 400A


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Battery Management Products


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Freescale in HEV/EV – Low Voltage Battery

Device GND = Chassis GND

= =

TCLK

RESET_A

TEST_A

Internal Bus

LV BMS

RESET

PA7

DC/DC Converter

Device GND = Battery Minus

BKGD/MODC

=

HV BMS

≈ =

≈

Inverter & Controller

Test Interface

PA6

PTE0 / EXTAL

Charger

Temp Sense Supply

TSUP

Reset Control Module

VOPT VBAT Sense Module (AAF, and optional Input)

VSENSE PTE [1:0]

Reset Generation and Test Entry

Periodic Interrupt

M68HCS12 CPU

Interrupt Control Module

ALU

D2DDAT2

D2DI

PTA DDRA

SS

SPI

16 Bit - ADC

VTEMP

D2DDAT4 D2DDAT0

PD0 VREG 1.8V Core 2.7V Flash

MISO

Internal Chip Temp Sense with optional external input

D2DDAT1

PD4

SCK MOSI

Die To Die Interface

D2DDAT5

PD5 PD1

Wake Up Control Module (with Current Threshold and Current Averaging)

D2DINT

PC1

PA0

PTB3 (L0)

MCU Die 4 Channel Timer

PTB2

Cascaded Voltage Regulators VDDH = 2.5V (D2D Buffer) VDDL = 2.5V (Internal Digital) VDDX = 5V (MCU Core)

GPIO

PTB1

SCI LIN Physical Layer

PTB0

BIAS

MCU Die S12 0.18um SGF


GNDSUB

GNDSUB

LIN

VSUP

VDDL

VDDX

VDDH

VDDD2D

VDDRX

VSSD2D

VSSRX

Analog Die

GNDSUB

PA1

ISENSEL

D2DDAT6

PD6

PA2

ISENSEH

D2DDAT3

PD3

PD2

QFN 48ld ► Optical Inspection capable through Wetable Flanks / dimple leads ► No need for X-Ray at manufacturing

ADCGND

Current Sense Module (PGA with auto Gain Control)

D2DDAT7

PD7

Dataflash 4k Bytes with ECC RAM 6k Byte

► 7x7

AGND

16 Bit - ADC

D2DCLK

PC0

Flash 128k Bytes with ECC

PA3

ADC Regulator

Debug Module include 64 byte Trace Buffer RAM

DGND

Package

PA4

Low Pass Filter And Control

Interrupt Module

CPU Register

VDDA

16 Bit - ADC COP Watchdog

GNDSUB

PA5

PLL with Freq. Modulation option OSC Clock Monitor

Trimming / Calibration

Single-Wire Background Debug Module

LGND

TEST

Amplitude Controlled Low Power Pierce Osc.

Internal Bus

PTE1 / XTAL

Analog Die SMOS8MV 0.25um

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Intelligent Battery Sensor ASSP VDDA ADC Supply

Key Characteristics • MCU S12 (16-bit) • Flash 128k (Options: 32k/64k/96k) • Data Flash 4k • RAM 6k • PL / WD LIN / YES • Standby Current 4-600V Plugin Capability

Extended Electrical Drive

Short Electrical Drive

4 to 10 kW 12 to 42V

Power Assist

Power Assist

Power Assist

2 to 4kW / 12V





Start/Stop

Start/Stop

Start/Stop

Start/Stop

Start/Stop

Conventional ICE

Conventional ICE

Downsized ICE

Downsized ICE

Downsized ICE

Electrical Assistance & Energy Mgt.

Full Electric

Full Electrical Drive

Electrical Drive Capability


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Freescale Power Technology Outlook

Traction Motor Inverters (GaN) 1500V/1.0 mohm*cm2

Traction Motor Inverters (IGBTs actual generation) 600-1000V Up to 400A 1.6-2.0V Vcesat (depending on switching capability) Stop/Start (HDTMOS) >20V 500 A Peak < 1 mOhm Rdson Relay Replacement (HDTMOS & LFET) 40V (extending to 65V) 150A Peak

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