Address to Advances In Automotive conference, Rockingham, February 2011. Describes how power electronics enables incremental improvements in fuel economy and CO2 emissions.

1. The Role of Power Electronics in
Reducing Fuel Consumption and Emissions
Andrew Stewart
10 February 2011
Advances in Automotive
andrew.stewart@irf.com
+44 (161) 705-1528
+44 (7711) 663820
auto.irf.com
COMPANY CONFIDENTIAL 1

2. Agenda
The Role of Power Electronics in
Reducing Fuel Consumption and Emissions
Brief introduction to International Rectifier
What is a hybrid?
Biggest Bang for the Buck
Examples of electrification
Handling power
Questions
COMPANY CONFIDENTIAL 2

3. About International Rectifier
NYSE: IRF
Rear Wiper
Class D Steering
• Headquarters: El Segundo, CA High End Car HIFI
• Fabs: Newport, Wales; Temecula, CA
HVAC
• Assembly: Tijuana, Mex; Carsem, Malaysia PTC-Heater
• Automotive Design Centers: Aix-en-
Fuel Pump
Provence, France; Pavia, Italy; El Segundo,
CA Window Lift
Power Seats
• Semiconductor technologies: MOSFET, HV HID Lighting
Oil Pump
IC; IGBT; Protected FET
Direct Fuel Injection
Glow Plugs Solenoids
Braking
COMPANY CONFIDENTIAL

4. IR: A Proud History in Electric Vehicles
1912 Baker Electric Car
• World’s first solar powered
automobile
• Panel mounted array of
silicon solar cells developed
in 1958 by IR
• 1270kg with batteries
• 10 640 cells – 20kg – 2.4m²
• 3HP electric motor
• Maximum speed 30km/h
• Range 80km
COMPANY CONFIDENTIAL 4

5. EV, Fuel Cells… not today
Source: A Short Field Guide to Hybrids, Green Car Congress
COMPANY CONFIDENTIAL 5

6. New Automotive Innovation & Growth Team Roadmap
Source: Department for Business, Innovation & Skills (BIS); UK Government
http://www.bis.gov.uk/policies/business-sectors/automotive/new-automotive-innovation-and-growth-team
COMPANY CONFIDENTIAL 6

7. Where are we now?
240
CO2 Emissions Regulations, Europe 1990 - 2030
• Multi point fuel injection (gasoline)
220 • Common rail injection (diesel)
• Diesel engine downsizing
200
CO2 Emissions (g/km)
• Engine downsizing (mainly gasoline)
186 • Turbocharging
180 • High pressure common rail
• Cylinder deactivation
160 162 • Gasoline hybrids
• Electrification
140 140 • Full hybrids
125
120 120
100
95
• High downsizing
80 • Hybrids (micro & mild)
• Gasoline direct injection 70
60 • Diesel hybrids
40
1995 2002 2008 2012 2015 2020 2025
Source: Frost & Sullivan
COMPANY CONFIDENTIAL 7

8. Roadmap to the Zero-Emission Vehicle
Current ICE
Technology
Micro Hybrid
3 – 10kW
CO2
Mild Hybrid
15 – 20kW
Full Hybrid Electric
200+kW Vehicle
Fuel Cell Zero Emissions
Vehicle Vehicle
Time
COMPANY CONFIDENTIAL 8

9. Innovation – Fuel Economy & CO2
% CO2 Reduction / €100
0 2 4 6 8 10 12 % CO2
Reduction Cost (€)
Variable speed fan motor
2 20
Reduced friction mechanical components
4 50
Electrically Powered Hydraulic Steering
4 50
Improved vehicle aerodynamics
3 50
Electrically Powered Steering
5 90
Downsize engine capacity with turbo charging or
supercharging 12.5 350
Direct Injection & lean burn 12 450
Hybrid 33 1600
Variable valve actuation 6 300
Stop-Start with regenerative braking 7 450
Dual-clutch transmission 7 600
Stop-Start 3.5 350
Electric motor assist 5 1200
Source: King Review of Low Carbon Cars and IR Estimates
COMPANY CONFIDENTIAL 9

10. Power Steering – when is it needed?
Hydraulic compressors waste power when they are not needed
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11. Electric Replaces Hydraulic
Power Inverter
VBAT+
Input Shaft
Bus Current
filter sensors
bridge Cap sensors
AC M S
in
VBAT-
ia,b,c
Gate
Control drives
circuits
(PWM etc.)
0.15 - 0.3 l/100km saving
1.5 – 5% less CO2
Image courtesy of TRW Automotive
COMPANY CONFIDENTIAL 11

12. Variable Speed Fan Motor
100W electrical = 218 litres fuel saved by using PWM Fan control (*)
Or 0.15L/100km > 3.40g/km C02
Traditional system The new system
+ +
110W  2 Speeds 10W  Variable
 Stress  Smooth
PWM
R
 Noisy  Quiet
 €3  €6
 80% Cars  Green cars
- -
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13. Stop-Start Traffic?
Micro Hybrid Stop/Start
• Reinforced starter motor
• Saves 4 – 6% fuel/CO2
Micro/Mild Hybrid Stop/Start
• Belt-driven alternator-starter
• Saves 5 – 8% fuel/CO2
Mild Hybrid Stop/Start
• Adds regenerative braking
• Possible booster motor
• Saves 10 – 12% fuel/CO2
COMPANY CONFIDENTIAL 13

14. Stop Start: Integrated Starter-Generator
Image courtesy of CPT/GreenCarCongress.com
COMPANY CONFIDENTIAL 14

15. HVAC Compressor
Power Inverter
VBAT+
Input Shaft
Bus Current
filter sensors
bridge Cap sensors
AC M S
in
VBAT-
ia,b,c
Gate
Control drives
circuits
(PWM etc.)
Image © Delphi
COMPANY CONFIDENTIAL 15

16. Pre Pilot TDC After Post
Direct Injection
Cylinder 2
TRIG1 (GD2, Bank
1)
Pre
Pressure Pilot TDC After Post
Pmax Pma
Cylinder 3
TRIG2 (GD2, Bank
Pressure
Pmax 2) Pma
Patmo Pre Pilot TDC After Post Patm
200 uS
Cylinder 4
Intake Compression Explosion Exhaust
TRIG2 (GD1, Bank
Patmo
Intake Valves
Patm
2) Exhaust Valves
NOTE: Injectors 1&4 will be controlled together by one full-bridge driver (GD1), while injectors 2&3 will be
Intake Compression Explosion Exhaust
controlled by a second driver (GD2); therefore, the recharging of the boost capacitor must complement the
firing of the injectors sharing the same H-bridge.Intakecompanion IC's are necessary to control the two gate
Two Valves
drivers used to actuate the 4 injectors. Signal TRIG1 from either companion IC will initiate the actuation of
Exhaust Valves
the first half of the H-bridge (Bank 1), while TRIG2 initiates the second half (Bank 2).
Image © Robert Bosch GmbH
Gate Driver 1 (GD1) Gate Driver 2 (GD2)
Bank 1 Bank 2 Bank 1 Bank 2
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17. Power – Choosing the Right Package
RDS(ON), Power Dissipated
COMPANY CONFIDENTIAL 17

18. APC3 Assembly Concept
DBC carrier
Customer’s substrate
• Component can be pick-and-placed onto printed solder paste on the system board
or substrate in the same way a smaller component would be.
• Will enable customers to use SMT processes to integrate fully yielded, large area
IGBT and diode dies without having to complete subsequent wirebonding
processes (reducing cost and improving reliability).
• Emitter-up and collector-up to allow easy ½ bridge layouts.
COMPANY CONFIDENTIAL 18

19. Thank You
The Role of Power Electronics in
Reducing Fuel Consumption and Emissions
Brief introduction to International Rectifier
What is a hybrid?
Biggest Bang for the Buck
Examples of electrification
Handling power
Questions
COMPANY CONFIDENTIAL 19

20. The Role of Power Electronics in
Reducing Fuel Consumption and Emissions
Contact me:
Office: +44 (161) 705-1528
Cell: +44 (7711) 663820
Web: auto.irf.com
Email: andrew.stewart@irf.com
uk.linkedin.com/in/adlstewart
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