Report

Teaser, summary, work performed and final results

Periodic Reporting for period 1 - HiPERFORM (High performant Wide Band Gap Power Electronics for Reliable, energy eFficient drivetrains and Optimization thRough Multi-physics simulation)

Teaser

The European and global automotive industry currently faces the challenge of reducing CO2 emissions, since improving air quality and avoiding global warming is high priority on the agendas not only in Europe, but also in the rest of the world. With a share of approximately...

Summary

The European and global automotive industry currently faces the challenge of reducing CO2 emissions, since improving air quality and avoiding global warming is high priority on the agendas not only in Europe, but also in the rest of the world. With a share of approximately 23%, the transportation system in Europe contributes significantly to the total greenhouse gas emissions and global warming. By a tremendous increase of affordable and efficient electric and hybrid vehicles, Europe can pave the way for a decarbonized transport system. Nevertheless, this is only one of many important measures that are needed to fight global warming.

HiPERFORM will directly address this topic by investigating the industrial applicability of high-performance semiconductors with wide-band gap materials in the field of Smart Mobility. For this purpose, a holistic approach is selected including the entire supply chain - from the manufacturer of semiconductors as well as power modules through suppliers of development methods and tools to the system and ultimately the vehicle manufacturers. The integration of academic partners with a high level of competence in these domains completes this approach. On the other hand, specific requirements for power electronics are addressed in specific application areas, which include both power inverters in the vehicle, electrical charging modules inside and outside the vehicle, as well as the associated development and test systems.

Therefore the project objectives for the HiPERFORM project can be summarized as following:
- Investigation on manufacturing processes and integration methods for GaN and SiC power switches for cost reduction and highest reliability
- Architectures and controllers which support highest frequencies in the e-powertrain of up to 50kHz to enable more efficient powertrains and up to 500kHz for usage in test systems
- Inverters, chargers and test systems for electric drivetrains with higher efficiency up to 98%, respectively 50% less spatial volume, less weight and less costs than today.

The expected project results will enable the European manufactures of WBG-based electric vehicle components, charging devices, and test systems to deliver excellent technologies for the automotive industry, to develop next generation affordable green vehicles. Affordable electric and hybrid vehicles will pave the way for the envisioned green transportation system. All citizens will directly benefit from longer driving ranges, less energy consumption, and lower prices due to the advanced technologies in next generation electric vehicles. Moreover, the European electronic components industry and system suppliers will tremendously profit from the expected results in this research project. The outcome will also safeguard current jobs as well as build the base for further growth in all sectors.

Work performed

WP1
Specification of Use Cases (D1.1) including detailed Requirements (D1.2)
Common understanding about the needs to establish the use-case demonstrators
Baseline for monitoring the project success
WP2
Optimized process to prepare base material to reduce defect density and future costs
First electrical test results on wafer level test of 100V GaN transistors
Increased breakdown voltages (reliability) for GaN components
Technology platform development including multiple process and layout DOE‘s for various device architectures
WP3
Design optimization framework for charging systems and inverters based on advanced WBG switches defined
Detailed investigations on robust control algorithms and strategies for chargers, inverters and test systems
WP4
First prototype of double-sided cooled power module is available
First 3D thermal modeling for power modules was done
First reliability tests performed and lifetime models derived
WP5
Different approaches for simulating e-powertrain components were implemented and tested
Architectures / models for inverter, charger and test systems elaborated
WP6
Setup of project organization and initiation of close collaboration of all partners
Setup of dissemination activities and raising public awareness

Final results

In the first year of HiPERFORM, main focus was on the specification of the single use cases and starting the developments. Up to now first promising results beyond state of the art could be achieved. These are:

* Optimized process to prepare base material to reduce defect density.
* GaN epitaxy on CTE matched QST substrates developed towards higher VBD and lower growth time
* Fabricated devices on GaN buffers grown on CTE matched substrate (QST), towards increased breakdown voltages (reliability) for GaN components
* A first basic electrical functional 100V GaN HEMT device was designed and processed
* First european double sided cooled 1200V SiC Module available as a first prototype

Based on these results, reducing costs and reliability of GaN devices will be achieveable and end users will benefit in reduced prices.
Additionally, the newly developed SiC module will also pave the way for higher efficiency, higher switching frequencies and hence reduced volumes of power electronic components.
The detailed impacts need to be investigated in the upcoming years after the first prototypical implementations of the module in the planned use cases.

Website & more info

More info: http://www.hiperform.eu.