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Hybrid and
Electric Vehicle
Solutions Guide
Automotive
Solutions
www.ti.com/hev 2013
System Solutions for Hybrid and Electric Vehicles
Table of Contents
System Solutions for Hybrid and Electric Vehicles
Texas Instruments in Automotive Applications
Introduction to Electric Transportation
Why TI?
System Architecture of HEV/EV
Battery Management
Introduction to Battery Management
Battery Management Systems
Battery Management: Applications bq76PL536A-Q1 Stackable Monitor, Protector and Balancer for Three- to Six-Series
Li-Ion Cells bq76PL536A Evaluation Module
Power Conversion Systems
Introduction to Power Conversion
DC/DC Converter Using UCC2895-Q1
DC/DC Converter Using C2000™ Piccolo™ MCUs
C2000™ Piccolo™ F2802x Family
C2000™ Digital Power DC/DC Developer Kits
Charging and Charging Infrastructure
Introduction to Charging and Charging Infrastructure
AFE031 Integrated PLC Analog Front End
PLC Developer Kit
TI PLC Modem Development Kit (TI PLC DK)
Charging Systems – AC Levels 1 and 2 (Onboard)
Charging Systems – DC Level 3 (Offboard)
AC/DC Converter with PFC using C2000™
Piccolo™ MCUs
AC/DC Development Kits with C2000™ MCUs
Why Piccolo™ MCUs?
Piccolo™ MCUs F2802x vs. F2803x
ControlSuite™ Software
Power Factor Correction with UCC
UCC28070-Q1 Two-Phase Interleaved Constant-
Current-Mode (CCM) Power Factor
Motor Control
Introduction to Drive and Motor Control
Safe Motor Control with TMS570 ARM
®
Cortex™-R4F
Safe Motor Drive with DRV32xx family
Introduction to Functional Safety
Safe Motor Control using TPS65381-Q1
Safe Motor Control with TMS570 ARM Cortex-R4F
Start/Stop Function
Introduction to Start/Stop
Power Management for Start/Stop Function
Start/Stop Function Using TI Analog Products
TPS40210-Q1 Boost Converter
TPIC74100-Q1 Buck-Boost-Converter
Integrated Switches
TPS40090-Q1 Four-Channel Multiphase
Buck DC/DC Controller (or Boost)
LM5122 Wide Input Range Synchronous Boost Controller with Multiphase Capability
Start/Stop Function Using the C2000™
Piccolo™ MCU
E-Bikes and Small Task-Oriented Vehicles (STOVs)
Introduction to E-Bikes and Small Task-Oriented
Vehicles (STOVs)
STOV Products
bq78PL116 Integrated Gas Gauge, Protection and Active Cell Balancing Controller for Up to
16-Series Li-Ion Cells bq77PL900 Standalone and Host-Controlled
Battery Protector for Five- to 10-Series
Li-Ion Cells bq77910 and bq77908 Standalone Precision
Protector for Four- to 10-Series Li-Ion/
Phosphate Cells bq78412 Pb-Acid Battery State-of-Charge Indicator with Run-Time Display bq77PL157A Stackable Overvoltage Protector for
Three- to Six-Series Li-Ion Cells
DRV8312-C2-KIT Motor Driver ICs
DRV8301 Brushless DC Motor Pre-Driver with
Dual-Shunt Amplifiers and a Buck Converter
Digital Motor Control for E-Bikes, Scooters and
STOVs Evaluation Module
C2000™ High-Voltage PFC and Motor Control
Developer Kit
Microcontroller Product Overview
Isolation and Analog Products
Introduction to TI Isolation Products
ISO7221X Dual-Channel, 25-Mbps Digital Isolator
SN6501 Transformer Driver for Isolated
Power Supplies
AMC1203 Isolated ADC (1-Bit, 10-MHz,
Second-Order, Isolated Delta-Sigma Modulator)
Analog Products Overview
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System Solutions for Hybrid and Electric Vehicles 2013
Texas Instruments
System Solutions for Hybrid and Electric Vehicles
Texas Instruments in Automotive Applications
Texas Instruments (TI ) is committed to providing superior cost-efficient solutions to the transportation market, along with excellent product documentation, on-time delivery and conformance to specifications.
TI supports transportation industry requirements and continues to add to our transportation portfolio. With more than 30 years of experience serving customers with demanding requirements, TI can help you achieve the quality, reliability and cost goals to succeed in today’s marketplace.
TI is fully committed to automotive quality; we have a dedicated quality organization and a zero-defect strategy in place. We are TS16949 certified and a preferred supplier to major car manufacturers.
Introduction to Electric Transportation
Electric transportation is not a new phenomena; in fact, the concept has been around for more than 100 years. However, given growing environmental sensitivities, long-term supply concerns, fossil fuel prices and improved technology, there is a strong motivation to further accelerate this market segment.
Government regulations like the
130-g/km (and future planned 95-g/km)
CO2 average emission limits for car manufacturers in Europe are also catalysts behind new electrified transportation alternatives. With the adoption of more electronics, vehicles become safer, exhibit higher performance, and are more efficient.
Electric transportation is a key element within the overall renewable energy landscape. Energy for charging is expected to come from renewable sources like wind-, solar- or waterpowered plants. Home and public charging stations will also become more prevalent and can take advantage of off-peak charging (nighttime) and green energy sources such as wind.
With a full range of analog and embedded processing products, TI is at the forefront of helping to bring safer, affordable and more efficient electric transportation solutions to market. TI’s solutions for this industry range from optimized and dedicated integrated circuits to full system-level solutions to help our customers optimize and accelerate product development.
TI’s experience in diverse markets such as industrial control, industrial motor drives, digital power supplies, smart metering and grids, wired and wireless communications, consumer electronics, and energy efficiency enables engineers to meet increasing needs for higher speeds, higher precision, lower power and more robust equipment – all while maintaining the high standards of quality and reliability that the automotive and transportation market demands.
Within this guide, you will find solutions and support for your hybrid and electric vehicle application designs in the following categories:
Different types of hybrid and electric vehicles
Feature
Start/stop alternator
Start/
Stop
a
Micro
Hybrid
a
Mild
Hybrid
a
Full
Hybrid
(Parallel)
a
Regenerative breaking
a a a
Electric torque assist
Electric and combustion drive
a a a
Only electric drive possible
Plug-in capability
a
Full
Hybrid
(Serial)
a a a
Full
Electric
a a a
Different types of hybrid and electric vehicle concepts exist in the market.
Texas Instruments offers leading-edge solutions for all systems, from a basic start/stop function to a fully integrated plug-in electric vehicle. This guide will give an overview of the various functions and also cover product highlights from various areas. For the latest information, see TI’s website,
www.ti.com.
Texas Instruments
System Solutions for Hybrid and Electric Vehicles 2013
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3
System Solutions for Hybrid and Electric Vehicles
Why TI?
Innovative semiconductor solutions
• Making advanced automotive and transportation devices more flexible, affordable and accessible.
• Addressing growing needs in energy efficiency, power and battery management, wired and wireless connectivity, and performance and precision.
Complete portfolio
• Amplifiers, data converters, interfaces, power management, isolation, logic, DSPs, MCUs and wireless connectivity.
• Catalog, application-specific, enhanced and custom IC options.
• Experienced automotive and transportation sector supplier with a full range of AEC Q-100-certified analog and embedded processing technologies and products.
Quality and reliability
• Experience in serving the automotive market for more than 30 years.
• Ability to serve customers of all sizes with a variety of supplier chains and needs.
• Long product lifetimes and a flexible product obsolescence policy, ensuring continuity of supply.
• Worldwide manufacturing and R&D capabilities.
• Member of industry-standard organizations and alliances.
Commitment
• Design support
• Tools
• Training
• Distribution
Introduction to the guide
This Hybrid and Electric Vehicle
Solutions Guide is intended to help you explore TI’s IC solutions as the various transportation sectors become increasingly electrified on a path toward energy efficiency and sustainability. This guide features several system block diagrams, followed by details about key devices and support functions.
System Architecture of HEV/EV
The hybrid and electric vehicle system is built of several modules to form the drive train and energy storage system. The battery block (typically a
Li-ion chemistry in the range of 400
V) is managed and monitored by the battery management system (BMS) and charged via an on-board AC/
DC converter module, with voltages ranging from 110-V single-phase to
380-V three-phase systems. The DC/
AC inverter uses the high voltage of the battery to drive the electric motor, but also is used for regenerative breaking, storing energy back into the battery.
To connect the high-voltage battery to the conventional 12-V board net requires a DC/DC converter. The connection of a high-voltage battery to the inverter also requires a reversible
DC/DC converter in most cases. The complete HEV system has to meet specific safety requirements (up to
ASIL-D) that are specifically relevant for managing the high-voltage battery pack, as well as the drive train used for breaking.
Electrical
Motor/
Generator
DC/AC
Inverter
Motor Control
TI is very active in the industrial control segment and can combine extensive application experience with a strong background in the automotive space.
Several evaluation modules with hardware and software support will speed up development, while the product roadmap addresses future requirements.
Battery
Monitoring
DC/DC
Converter
(Reversible)
Energy Conversion
High-
Voltage
Li-Ion
Battery
DC/DC
Converter
(Full Bridge)
Battery
Management
AC/DC
Converter
(PFC + PLC)
Charger
12-V Board
Net
Low-
Voltage
12-V
Battery
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System Solutions for Hybrid and Electric Vehicles 2013
Texas Instruments
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