Characterization of a Si/SiC Fusion power module on an inverter/e-Drive testbench
H. Akabay, N. Gorte, K. Ezzeddine, Ch. Pannemann,
Infineon Technologies AG, Max-Planck-Str. 5, D-59581 Warstein
Abstract
The combination of silicon (Si) and silicon carbide (SiC) technologies offers significant cost and performance advantages. This study quantifies the efficiency of a Si/SiC based inverter system, highlighting its benefits in terms of reduced energy losses. The quantification is achieved using a laboratory inverter system with the Infineon HybridPACK™ Drive G2 Fusion power module combining both Si and SiC technologies. The evaluation is performed on a motor test bench consisting of two mechanically coupled 85 kW permanent magnet synchronous motors (IPMSM) at speeds of up to +/-5500 rpm and torques of up to +/- 250 Nm. This range ensures that operating points in both the constant torque and field weakening regions of the motor are covered. The experimental results show that inverter efficiencies more than 98.8% were achieved. Finally, the measured data was used to generate efficiency maps and simulate WLTP profiles for the Si/SiC Fusion module, which are then compared to the Si and SiC standard modules. Similarly, the obtained results under WLTP show that the Fusion module ensures improved vehicle range as compared to the Si and SiC modules.
I. Introduction
The automotive industry is undergoing a transformative shift towards battery electric vehicles (BEVs) to meet global sustainability goals, necessitating advancements in power electronics. Central to this evolution is the development of efficient traction inverters, which are crucial for optimizing energy efficiency, power density, and overall vehicle performance. While silicon (Si)-based insulated gate bipolar transistors (IGBTs) have been the cornerstone of inverter technology due to their cost-effectiveness, they face limitations in efficiency and high-temperature operation. Conversely, silicon carbide (SiC) metal oxide semiconductor field-effect transistors (MOSFETs) offer superior efficiency and thermal capabilities but are hindered by high costs and limited availability.
To address these challenges, hybrid power modules that combine Si and SiC technologies have emerged as a promising solution. These modules aim to strike a balance between cost and performance by leveraging the cost-effectiveness of Si IGBTs and the superior efficiency of SiC MOSFETs. This study focuses on the Infineon HybridPACK™ Drive G2 Fusion power module, which integrates 30% SiC and 70% Si components, designed to achieve near-full SiC efficiency at a reduced cost.
The research evaluates the efficiency of this hybrid module under various operating conditions using a sophisticated test bench with two mechanically coupled 85 kW permanent magnet synchronous motors (IPMSMs). The results are compared with traditional Si IGBT and full SiC modules, demonstrating the hybrid module’s exceptional efficiency, reaching over 98.8%. Additionally, simulations under the Worldwide Harmonized Light Vehicles Test Procedure (WLTP) highlight the module’s real-world benefits, showing a 2.9% increase in vehicle range compared to Si IGBTs.
This study underscores the significance of hybrid modules in enhancing inverter efficiency and vehicle performance, offering a viable solution for the automotive industry’s transition to sustainable transportation. By bridging the gap between cost and performance, the Si/SiC Fusion technology not only supports current advancements but also paves the way for future developments in power electronics.
