Electrifying efficiency: Michael Luett on how STMicroelectronics is revolutionising car electrification applications
The ongoing electrification of the automotive and transportation segments has increased the demand for semiconductor products, especially in high-voltage applications. Here, we talk to Michael Luett, Automotive Marketing Manager at STMicroelectronics (ST) and the latest contributor to Electrify Tomorrow, our exclusive webinar series, about some of the latest trends in power electronics.
Q: Hello, Michael. It’s a pleasure to talk to you about smart mobility. Firstly, can you give us some background on STMicroelectronics?
Thank you, it’s great to get the chance to discuss this fast-paced area of technology. In terms of context to the organisation, STMicroelectronics is one of the largest semiconductor companies in the world, with revenues of $17.3 billion last year. It’s headquartered in Geneva, Switzerland. We employ more than 50,000 people worldwide, with over 9,500 in research and development functions. So, we are indeed an engineering company at our heart. We have a worldwide presence with over 80 sales and marketing offices and a base of more than 200,000 customers.
Q: As you know, the semiconductor industry has seen some incredible growth in recent years. How has ST evolved during this period of rapid technological transformation?
ST is positioned as an integrated device manufacturer, meaning we have our own production facilities where we produce most of our products. We also rely, to a certain extent, on silicon foundries. Furthermore, ST acts as a silicon foundry for certain key customers and businesses. Our production locations include what we describe as front and back ends. We do the wafer processing on the front ends, mainly with eight and twelve-inch wafers. Meanwhile, we do the package assembly, final testing, and quality control at the back end. Our company's slogan, 'life augmented,' signifies that ST is present wherever electronic devices positively impact people's lives.
Q: From your experience, what are the critical drivers for your competing sectors and industries?
The market strategy is based on several long-term megatrends, including smart mobility, power and energy, the Internet of Things and 5G communication. Our end-market segments are mainly automotive, industrial, personal electronics, communication equipment, computers, and peripherals. Automotive is a fascinating segment, with revenues growing by 33% last year. As one of the largest semiconductor vendors in the automotive industry worldwide, we provide innovative solutions to help our customers make driving safer, greener, and more connected for everyone. This means that we offer the necessary products and solutions to solve the complete range of automotive applications with innovation in traditional car electronics, as well as solutions for electrification and digitalisation.
Q: Can you give us an overview of how power electronics subsystems have evolved to meet the demand for more efficient and higher-performing electric vehicles?
The high-power electronics architecture typically includes the DC-AC traction inverter, which drives the electric motor and has the highest output power among all Automotive applications. DC-DC converters manage power conversion between different voltage domains, such as high and low-voltage systems. Other key components include the onboard charger, for charging the high-voltage battery from AC mains or public charging stations, as well as the air conditioning compressor and PTC heater. An electric vehicle’s high-voltage battery can be recharged in two ways: DC fast charging, offering up to 350kW to recharge large batteries in about 20 minutes, and AC charging via the OBC, typically offering up to 11kW. While electric vehicles typically have a high-voltage battery, they also require traditional automotive ECUs powered by 12V or sometimes 48V systems, necessitating DC-DC converters. So, it is a highly integrated environment with lots of technical considerations.
Q: Allied to that, what are some of the important technology trends you see in power electronics subsystems for electric vehicles?
One market trend is that the DC/DC converter and the onboard charger are merging into one single unit - the so-called combo - and that the onboard charger is becoming a bi-directional system. So now the vehicle is not only charged from the power grid but can also deliver power from the battery pack back into the grid, which is called Vehicle-to-Grid (V2G). A semiconductor company like ST must offer various power technologies to enable a highly efficient operation of these power electronic systems with minimum power losses. These include IGBTs, silicon carbide MOSFETs (SiC MOSFET), high-voltage silicon MOSFETs, gallium nitride (GaN) transistors, and also power modules that provide a very high level of integration and power density.
Michael Luett
Automotive Marketing Manager
STMicrolectronics
Q: How does ST ensure the right power technologies to ensure the operating range for different applications and requirements?
It is essential to offer a wide range of choices so that customers can make the optimal choice for their technical and commercial requirements. For instance, under the umbrella of wide-bandgap-based products, we have silicon carbide MOSFETs from 650V up to 1700V, which enables very high-power density and a high switching efficiency – allowing customers to reduce size, weight and cooling requirements of high-power systems. We are already in volume production with three technology generations, mainly for 650V and 1200V, which is perfectly suitable for vehicles with 400V and 800V batteries.
Then we have gallium nitride, which is currently in development for automotive and is already in volume production for non-automotive applications, like laptop and mobile phone chargers. For automotive, we are planning 650V and 100V devices. The utilisation of high-power density and fast switching solutions in DC/DC converters and onboard chargers will allow for the downsizing of passive components and cost reduction.
Also, with silicon-based products, we have high voltage MOSFETs and IGBT, where we offer a variety of power families that are optimised in different technical aspects so that we can propose the best device for whatever application or requirements.
Q: Can you give us some product highlights that indicate your continued innovation and development of power electrics that can support e-mobility applications?
Sure. The HU3PAK is a compact topside cooling package that integrates silicon carbide MOSFETs in a small SMD solution with excellent thermal performance. Qualified to AEC-Q101 standards, it supports up to 1200V ratings. The Kelvin source pin enhances switching performance by separating the power section from the gate control, and the design meets high-voltage isolation requirements. When we consider the silicon carbide MOSFET, the HU3PAK houses all available options from 650V up to 1200V with very low ohmic variants, dissipating thermal energy through both the pins and the top side for easy heatsink mounting.
Meanwhile, the ACEPACK SMIT package integrates half-bridge configurations, offering a compact solution with high power density, low stray inductances, and superior thermal performance. It optimises the efficiency of switching applications and is available in 650V and 1200V ratings.
Finally, there is ACEPACK Drive—a high-performance, direct liquid-cooled power module designed for traction inverter applications in electric vehicles, trucks, and buses. It supports up to 300kW output power and offers options with IGBTs and diodes or silicon carbide MOSFETs. The voltage options are 750V and 1200V, suitable for 400V and 800V batteries.
These products highlight our commitment to advancing e-mobility technology through innovative and efficient power electronics solutions.
Q: Looking ahead, what future developments or innovations can we expect from STMicroelectronics in automotive power electronics?
We continuously invest in research and development to push the boundaries of power electronics in the automotive sector. We are focusing on enhancing our power modules’ efficiency and performance, particularly through advanced materials like silicon carbide and gallium nitride. These materials are pivotal in optimising the switching efficiency and reducing power losses, which are crucial for electric vehicles.
We are also expanding our range of system demonstrators, including physical system demonstrators, to showcase the performance of our technologies in real-world applications. This includes comprehensive system designs for traction inverters, onboard chargers, and various DC-DC converters. We aim to support rapid prototyping and quick implementation of our devices through evaluation boards, proof of concepts, and reference designs.
Moreover, we are committed to building competencies beyond the components we ship. This involves offering extensive technical support, simulation tools, and designer assistance to help our customers optimise their designs. We are also exploring new topologies and control methods to further enhance the performance of power systems in electric vehicles.
In summary, STMicroelectronics aims to remain at the forefront of the automotive industry’s transformation towards more efficient, sustainable, and connected mobility solutions.
Michael Luett recently participated in our exclusive webinar series, Electrify Tomorrow, talking in greater detail about optimising efficiency in car electrification—with a specific focus on choosing the right semiconductor solution to achieve optimum efficiency in onboard chargers and DC-DC converters. Click here to watch the webinar.
You can also learn more about Avnet Silica’s Automotive, Power, Vehicle Electrification and EV Charging solutions.
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