Commercial, construction and agricultural vehicles

Commercial, Construction and
Agricultural Vehicles
Application Guide
www.infineon.com/cav
2
Content
Introduction to Commercial, Construction and Agricultural Vehicles (CAV)
5
Body Applications
6
Body ECU
7
Seat Control Module
8
LED Lighting
9
Low Voltage Motor Control
10
Brushless DC Motor Control
11
Brushed DC Motor Control
12
Unidirectional Control of DC Motor
13
Hybrid Electric Solutions
14
Auxiliary Applications
15
Powertrain Inverter
16
Valve Control
17
Hydraulic Management System
18
Pneumatic Management System
19
3
4
Introduction to Commercial, Construction and
Agricultural Vehicles (CAV)
As the demand for fuel and operation efficiency rises,
electrification is an increasingly attractive option for
commercial, construction and agricultural vehicles (CAV).
Going electric offers two key benefits: compliance with
stricter legislation regarding emission levels and energy
efficiency, along with increased process efficiency and
yield rates. By opting for hybrid or fully electric drivetrains, CAV operators can reduce or even eliminate their
fuel consumption and CO2 emissions. More important,
electric drivetrains require less maintenance, and are
therefore more reliable and productive. And, as automation becomes increasingly widespread, the global
demand for electronics is also on the rise in order to boost
production and meet the demands associated with
a growing world population and less agricultural land.
Traditionally, commercial, construction and agricultural
vehicles (CAV) have relied on two main technologies – a
cen­tral combustion engine provides mechanical power
while hydraulic systems control huge forces, normally at
very low speeds. Nowadays, electric drives controlled by
modern power electronics can be used as a complement or
substitute for both. Electric machines can support or fully
replace the combustion drivetrain in the engine. In a hybrid
design, the combustion engine delivers part of the propulsive power, while the electric drive provides torque for peak
loads. Such a system reduces fuel consumption and allows
energy to be recovered during braking. This energy can later
be used to accelerate the vehicle and boost fuel efficiency.
Furthermore, an electric motor can also operate as a
starter-generator, reducing the complexity of the drivetrain
by combining these two parts – a design concept similar
to the hybrid drive for the automotive industry. A diesel-­
electric drivetrain concept, in which the combustion engine
ensures efficiency while driving a generator, is another
alternative. Here, the generator provides the electric power
needed to operate the vehicle, which is always driven
electrically. A battery stores energy recovered during
deceleration to ensure an independent supply of energy –
regardless of whether or not power is being generated. The
gearbox and clutch are eliminated and, unlike combustion
engines, electric machines can provide maximum torque at
zero speed, making them ideal for heavy-duty applications.
Finally, in the case of electric drives, an on-board energy
storage solu­tion, such as a battery or fuel cell, can provide
enough energy to operate the vehicle for a reasonable
length of time. In an electric forklift truck, for example, this
could be a shift of several hours while a few minutes may
be sufficient for an urban bus that can recharge at each bus
stop. Eliminating the combustion engine also represents a
major step in improving availability and reliability.
With proven expertise in CAV and a comprehensive portfolio of robust, high-quality control and power semiconductor solutions, Infineon helps designers and developers to
engineer CAVs that deliver improved fuel economy, productivity and reliability.
Visit our application solutions site for comprehensive system block diagrams, products
and resources to complete your design.
Seat Control Management for 24 V
24 V
LIN Transceiver
Linear VREG
DC/DC VREG
TLE6389-2GV
AURIX™
TC22xx
Motor Driver
Communication
(Optional)
VBATT or Switched
CAN Transceiver
NovalithIC™
Power Half-Bridge
BTN8982TA1)
NovalithIC™
Power Half-Bridge
BTN8982TA1)
Seat Movement
M Front-Back 10 A
Seat Height
M Up-Down 10 A
NovalithIC™
Power Half-Bridge
BTN8982TA1)
M
NovalithIC™
Power Half-Bridge
BTN8982TA1)
Supply
CAN
LIN
NovalithIC™
Power Half-Bridge
BTN8982TA1)
Signal Conditioning
Temperature
Sensor
Position Sensor
NovalithIC™
Power Half-Bridge
BTN8982TA1)
Seat Width
Wide-Narrow 10 A
Seat Angle
M Vertical-Down 10 A
High-Side Driver
HiC PROFET™
BTT6010-1EKA
www.infineon.com/cav-seat
M
1) External Protection for VBATT > 40 V
Massage 5 A
PROFET™
BTT6030-2EKA
M
HiC PROFET™
BTS50085
M
Cooling Fans 3 A
Seat Heater 10 A
5
Body Applications
24 V body applications for trucks and agricultural vehicles
can be divided into three sections: truck body Electric
Control Unit (ECU), seat control and LED lighting. The suc­
cess of each hinges on the use of top-quality 24 V solutions
specifically engineered for the high demands of CAVs.
Design challenges common to body applications must also
be overcome, whether involving the limited space avail­
able for a body ECU and seat control, or the high efficiency
demands of LED lighting.
Nowadays, a truck ECU has to master an ever-growing
list of functions despite ever-decreasing board space.
Achieving this requires products for 24 V systems with a
high level of integration. Seat control modules based
on 24 V require, first and foremost, a compact design with
integrated motor drivers. Since lighting has become a
major differentiator in vehicle design, there is a soaring
demand for highly flexible solutions that accommodate a
broad range of LED configurations in trucks, such as
those with a highly efficient and flexible DC/DC controller.
What’s more, it’s important to know when a LED has
burned out, which is why a diagnostic feature has been
integrated into the LED rear light module. But there is
also pressure to design a module that is both highly func­
tional and low in cost.
www.infineon.com/cav-body
6
Body Application
Body ECU
Headlight
Assembly
Servo
Driver IC
Highbeam
75 W
Lowbeam
70 W
PROFET™
PROFET™
Indicator Marker
Fog
DRL
2x 21 W 10 W 2x 70 W 2x 21 W
Marker Indicator
10 W 2x 21 W
Lowbeam
70 W
Highbeam
75 W
PROFET™
PROFET™
Headlight
Assembly
M
PROFET™
PROFET™
PROFET™
LEDs
High-Side Driver
LIN
Transceiver
CAN
CAN
Transceiver
1x … 4x LIN
CAN
System
Basis Chip
(Optional)
+24 V
VBATT
DC/DC
Regulator
16/32-bit
Microcontroller
XC22xx Family
AURIX™ 32-bit
Multicore/
Lockstep
Microcontroller
Low-Side Driver
LIN
Relays
FlexRay
Transceiver
Communication
FlexRay
HITFET™
Interior Light
Body Control Module for Trucks
Supply
Manual or
Static Automatic
Leveling
High-Side Driver
PROFET™
PROFET™
PROFET™
PROFET™
PROFET™
Rear Light
Assembly
Rear Light
Assembly
Indicator Fog
2x 21 W 2x 21 W
Brake Backlight
2x 21 W 21 W
System Benefits
„„ Reduced board space due to integrated functionality
„„ PROFET™+ 24V provides excellent diagnostic and
protection features and a high current sense accuracy,
even for the smallest loads, such as LEDs
„„ Supports the “Limp Home” functional safety concept
Basic
LED Driver
Brake Backlight
2x 21 W 21 W
Reverse Indicator
70 W 2x 21 W
„„ Maximum design flexibility and a lower design outlay
due to identical footprint & pin-compatibility
„„ Automotive LED driver products supporting the
transition of lighting solutions to LED exclusively
Suggested Products
Product
Description
AURIX™
Scalable 32-bit TriCore™ microcontroller family from single- to multicore (PRO-SIL™)
Supply ICs
Voltage regulators, DC/DC converters
SPIDER, HITFET™
Single- and multi-channel protected high- and low-side switches
LITIX™ Basic
Scalable linear current sources family for automotive LED applications
SBCs, Network Transceiver
System basis chips, CAN, LIN and FlexRay transceiver
PROFET™
Single- and multi-channel protected high-side switches
www.infineon.com/cav-bcm
7
Body Application
Seat Control Module
Seat Control Management for 24 V
Signal Conditioning
(Optional)
VBATT or Switched
24 V
CAN Transceiver
LIN Transceiver
Linear VREG
DC/DC VREG
TLE6389-2GV
AURIX™
TC22xx
NovalithIC™
Power Half-Bridge
BTN8982TA1)
Seat Movement
M Front-Back 10 A
Seat Height
M Up-Down 10 A
NovalithIC™
Power Half-Bridge
BTN8982TA1)
M
NovalithIC™
Power Half-Bridge
BTN8982TA1)
Supply
LIN
Communication
Position Sensor
NovalithIC™
Power Half-Bridge
BTN8982TA1)
Motor Driver
Temperature
Sensor
CAN
NovalithIC™
Power Half-Bridge
BTN8982TA1)
NovalithIC™
Power Half-Bridge
BTN8982TA1)
Seat Width
Wide-Narrow 10 A
Seat Angle
M Vertical-Down 10 A
High-Side Driver
HiC PROFET™
BTT6010-1EKA
M
1) External Protection for VBATT > 40 V
Massage 5 A
PROFET™
BTT6030-2EKA
M
M
Cooling Fans 3 A
System Benefits
„„ System-in-a-package solutions for high-power integrated
and protected motor control
„„ Reduced board space due to integrated functionality
HiC PROFET™
BTS50085
Seat Heater 10 A
„„ Protected load control with sophisticated diagnostic
features
Suggested Products
Product
Description
AURIX™ TC22xL
Scalable 32-bit TriCore™ microcontroller family from single to multicore (PRO-SIL™)
NovalithIC™ BTN8982TA
Integrated half-bridge driver
High-Current PROFET™
Smart low-ohmic high-side switches for heating applications
PROFET™+ 24V
Smart high-side switches for 24 V applications
TLE6389
DC/DC converter (automotive)
Network Transceivers
LIN and CAN transceivers
www.infineon.com/cav-seat
8
Body Application
LED Lighting
Supply
+12 V from Battery/
+12 V Switched
System Basis
Chip
(SBC)
Communication
CAN
LIN
Stepper
Motor Driver
M
Position
Sensor
Light Leveling
Stepper
Motor Driver
M
Position
Sensor
Daytime Running Light/
Position Light
Power LED Driver
16/32-bit
Microcontroller
XC22xx
Headlight Lowbeam
LED Driver
(Optional)
8-bit
Microcontroller
XC8xx
Motor Driver / Beam Control
Curve Light
Decentralized
Light Control Module
Power LED Driver
Turn Indicator
Power LED Driver
Position Light or Fog Light
Power LED Driver
System Benefits
„„ Automotive LED drivers for high-brightness LEDs
„„ LED driver ICs support various DC/DC topologies
(buck, boost, SEPIC)
„„ Microcontroller peripherals for light control with a
low CPU load
„„ System basis chips combine the supply, network transceiver and monitoring functions in a monolithic device
Suggested Products
Product
Description
AURIX™
32-bit high-performance microcontroller family
LITIX™ Basic
Scalable linear current sources family for automotive LED applications
Network Transceivers
LIN and CAN transceivers
Position Sensors
Magnetic position sensor and angle sensors
www.infineon.com/cav-lighting
9
Low Voltage Motor Control
No matter which kind of motor – brushless DC, brushed
DC or unidirectional – motor control for trucks and agricul­
tural vehicles has to be extremely robust and come with
the diagnostic and protective functions required in CAVs.
But that’s not all – the motor control industry faces
growing pressure to find new ways of, among other things,
increasing energy efficiency. With software assuming a
central role, the systems themselves are becoming ever
more complex.
www.infineon.com/cav-motorcontrol
10
Low Voltage Motor Control
Brushless DC Motor Control
+24 V from Battery
Integrated System Supply
TLF35584 1)
Torque Sensor
3-Phase
Driver IC
Torque
IGBT
IGBT
IGBT
Hall IC
M
Wheel Speed
Sensor
Sensor
Interface
Speed
Differential
Hall IC
32-bit
AURIX™
Lockstep
MCU
IGBT
IGBT
Rotor Position
iGMR Sensor
IGBT
Motor Current
6x OptiMOS™ T80 or 100V
MOSFETs
Rotor Position/Current Sense
CAN/LIN
1) Need of external protection for VBATT > 45 V
HS CAN Bus
System Benefits
„„ Integrated solution reduces the design outlay
„„ PWM control
„„ Discrete solution optimized for all motors thanks to
a broad selection of MOSFETs
„„ Protection functions, including SC, overload, OT and ESD
„„ Diagnostic functions, including open load, OT detection,
integrated OPAMP and current sense
Suggested Products
Product
Description
AURIX™
Scalable 32-bit TriCore™ microcontroller family from single to multicore (PRO-SIL™)
TLE9180
3-phase bridge driver IC for automotive safety applications (PRO-SIL™)
Position Sensor
Magnetic position sensor and angle sensors
ATV MOSFETs 80/100V
Single: n-channel 80 V/100 V MOSFET
TLF35584
System power supply with Integrated watchdog (PRO-SIL™)
IKW/IKQxxN60/N120/T/H3
Discrete IGBT PG-TO247/Plus 1200 V/600 V/8–120 A
www.infineon.com/cav-brushless
11
Low Voltage Motor Control
Brushed DC Motor Control
+24 V from Battery
DC/DC Power Supply
TLE6389-2GV
CAN
IGBT
TLE7250G1)
TLE6251DS1)
IGBT
M
32-bit MCU
TC22x
AURIX™
H-Bridge
Driver IC
TLE7181EM1)
TLE7182EM1)
IGBT
IGBT
Position
Sense
ADC
Current Sense
OptiMOS™ T80 or 100 V
4x IPB180N0854-02 or
4x IPB180N1054-02
1) With external protection against load dump 400 ms above 40 V
System Benefits
„„ Integrated solution reduces the overall outlay
„„ Discrete solution optimized for all motors thanks to
a broad selection of MOSFETs
„„ PWM control
„„ Protection functions, including SC, overload, OT and ESD
„„ Diagnostic functions, including open load, OT detection,
integrated OPAMP and current sense
Suggested Products
Product
Description
AURIX™
Scalable 32-bit TriCore™ microcontroller family from single to multicore (PRO-SIL™)
Network Transceivers
CAN transceivers
Driver ICs TLE7181/7182
MOSFET driver for H bridge configuration
ATV MOSFETs 80/100V
Single: n-channel 80 V/100 V MOSFET
TLE6389
DC/DC converter (automotive) for 24 V applications
IKW/IKQxxN60/N120/T/H3
Discrete IGBT PG-TO247/Plus 1200 V/600 V/8–120 A
www.infineon.com/cav-brushed
12
Low Voltage Motor Control
Unidirectional Control of DC Motor
Signal Conditioning
NovalithIC™
Power Half-Bridge
BTN8982TA1)
CAN
Communication
Position Sensor
CAN Transceiver
LIN
LIN Transceiver
(Optional)
AURIX™
TC22xx
M
NovalithIC™
Power Half-Bridge
BTN8982TA1)
NovalithIC™
Power Half-Bridge
BTN8982TA1)
M
NovalithIC™
Power Half-Bridge
BTN8982TA1)
Supply
Linear VREG
DC/DC VREG
TLE6389-2GV
VBATT or Switched
M
NovalithIC™
Power Half-Bridge
BTN8982TA1)
Motor Driver
Temperature
Sensor
M
NovalithIC™
Power Half-Bridge
BTN8982TA1)
High-Side Driver
HiC PROFET™
M
1) External Protection
for VBATT > 40 V
BTS50085
BTT6010-1EKA
System Benefits
„„ Integrated solution reduces design the design outlay
„„ Discrete solution optimized for all motors thanks to
a broad selection of PROFET™ switches
„„ PWM control
PROFET™
M
HiC PROFET™
M
BTT6030-2EKA
BTS50055
„„ Protection functions, including SC, overload, OT and ESD
„„ Diagnostic functions, including open load, OT detection,
integrated OPAMP and current sense
Suggested Products
Product
Description
AURIX™ TC22xL
Scalable 32-bit TriCore™ microcontroller family from single to multicore (PRO-SIL™)
NovalithIC™ BTN8982TA
Integrated half-bridge driver
High-Current PROFET™
Smart low-ohmic high-side switches for heating applications
PROFET™+ 24V
Smart high-side switches for 24 V applications
TLE6389
DC/DC converter (automotive)
Network Transceivers
LIN and CAN transceivers
www.infineon.com/cav-unidirectional
13
Hybrid Electric Solutions
Market trends, such as the drive for increased efficiency
and fuel economy, have become an indispensable feature
of contemporary CAV design. Electrification, in particu­
lar (for example of the drivetrain), is an attractive option
because it allows manufacturers to comply with everstricter legislation regarding emission levels and energy
efficiency. While at the same time, electrification also
allows operators to enjoy higher process efficiency and
yield rates. Electric drivetrains also less maintenance,
making them more reliable and productive.
Fuel economy is yet another benefit of hybrid or 100%
electric drivetrains. Fully electric engines, in particular,
potentially eliminate the consumption of fossil fuels
and help reduce the carbon footprint. Improved passenger
comfort and lower noise levels are additional pluses.
The net effect of going electric in CAV applications is evident to all – a better quality of life in our cities and
throughout the world.
The potential benefits associated with the electrification
of CAV drivetrains and auxiliary machines keep increasing.
An electric drivetrain has far fewer parts, especially moving
ones, resulting in fewer failures and maintenance issues.
Using electric rather than hydraulic power in CAV auxiliary
machines – including saws, balers and mowers – leads
to increased productivity by enabling higher speed and
accuracy.
www.infineon.com/cav-hev
14
Hybrid Electric Solutions
Auxiliary Applications
Phase Current/
Voltage
Measurement
IGBT Stage
Driver Stage
Power
Supply
Microcontroller
Power
Supply
DC-Link Capacitor
LV Battery
Case Temperature
Measurement
NTC Measurement
System Benefits
„„ Power-product portfolio including both power module
and discrete solutions
„„ Gate drivers featuring galvanic isolation
HV Battery
„„ Highly efficient 3-phase motor operation thanks to very
low conduction losses, even at high switching frequencies
„„ Broad 32-bit microcontroller solutions dedicated
to (H)EV applications
Suggested Products
Product
Description
FF450R12ME4A
EconoDUAL™ 3 half-bridge power module, 1200 V/450 A
FF600R12ME4A
EconoDUAL™ 3 half-bridge power module, 1200 V/600 A
FF900R12IP4V
PrimePACK™ 2 half-bridge power module 1200 V/900 A
FD/DF600R12IP4V
PrimePACK™ 2 high- and low-side chopper modules 1200 V/600 A
IKW/IKQxxN60/N120/T/H3
Discrete IGBT PG-TO247/Plus 1200 V/600 V/8–120 A
2ED300C17-S/ST
Half-bridge high-power IGBT-driver
1ED020I12-FA
Single-channel IGBT-driver IC
2ED010I12-XXX
Dual-channel IGBT-driver IC
www.infineon.com/cav-aux
15
Hybrid Electric Solutions
Powertrain Inverter
Phase Current/
Voltage
Measurement
IGBT Stage
Driver Stage
Power
Supply
Microcontroller
Power
Supply
DC-Link Capacitor
LV Battery
HV Battery
Case Temperature
Measurement
NTC Measurement
System Benefits
„„ Product portfolio supporting a wide range of motors,
generators and power classes
„„ Highly efficient 3-phase driver thanks to very low
conduction losses, even at high switching frequencies
„„ Isolation-integrated in gate driver
„„ Wide range of 32-bit microcontroller solutions dedicated
to (H)EV applications with an extremely cost-effective
resolver interface
Suggested Products
Product
Description
FF450R12ME4A
EconoDUAL™ 3 half-bridge power module, 1200 V/450 A
FF600R12ME4A
EconoDUAL™ 3 half-bridge power module, 1200 V/600 A
FF900R12IP4V
PrimePACK™ 2 half-bridge power module 1200 V/900 A
FD/DF600R12IP4V
PrimePACK™ 2 high- and low-side chopper modules 1200 V/600 A
IKW/IKQxxN60/N120/T/H3
Discrete IGBT PG-TO247/Plus 1200 V/600 V/8–120 A
2ED300C17-S/ST
Half-bridge high-power IGBT-driver
1ED020I12-FA
Single-channel IGBT-driver IC
2ED010I12-XXX
Dual-channel IGBT-driver IC
www.infineon.com/cav-inverter
16
Valve Control
Valve Control
Whether hydraulic or pneumatic, control valve manage­
ment systems must have the right characteristics and
functions to meet CAV demands. To efficiently control an
inductive valve, a hydraulic management system has
to be precise and robust enough to withstand harsh envi­
ronments and engineered to provide the right selection
of protective and diagnostic functions. A pneumatic management system, on the other hand, is typically chosen
because it’s cost friendly and easier to integrate (no need
for a reservoir) than its hydraulic counterpart, but can
still withstand a harsh environment.
www.infineon.com/cav-valve
17
Valve Control
Hydraulic Management System
+24 V
Pedal
TLE4253
TLE4271
BTT6050-2EKA
Inlet
TLE4990
Inlet
OUT
VBATT
+
-
32-bit MCU
XMC4x002)
or
BTT6030-1EKA
16-bit MCU
XC2000
Pump
BTT6050-2EKA
Outlet
or
TLE7250G1)
TLE6251DS1)
32-bit MCU
TC22x
AURIX™
Outlet
Reservoir
CAN-Bus
Chassis
1) If the ECU is permanently supplied, you may need to add external protection against load dump 400 ms above 40 V.
2) Not AEC-Q100 qualified
System Benefits
„„ Integrated solution reduces the design outlay
„„ Pin-to-pin compatibility between the 12 and 24 V
PROFET™+ families
„„ Family concept with RDS(on) scalability reduces
the engineering outlay
„„ Protection functions, including SC, overload, OT and ESD
„„ Diagnostic functions, including open load, OT detection,
integrated OPAMP and current sense
„„ One-stop shop: supply, microcontrollers, actuators
and sensors
Suggested Products
Product
Description
AURIX™/XMC
32-bit high-performance microcontroller families (automotive/industrial)
PROFET™+ 24V
Smart high-side switches for 24 V applications
Network Transceivers
LIN and CAN transceivers
Hall Sensors
Magnetic speed sensors
Supply ICs
Linear voltage regulator
TLE6389
DC/DC converter (automotive)
www.infineon.com/cav-hydraulic
18
Valve Control
Pneumatic Management System
+24 V
Pedal
TLE4253
TLE4271
BTT6050-2EKA
Inlet
TLE4990
Inlet
OUT
VBATT
+
-
32-bit MCU
XMC4x002)
or
BTT6030-1EKA
16-bit MCU
XC2000
Compressor
Pump
BTT6050-2EKA
Outlet
or
TLE7250G1)
TLE6251DS1)
32-bit MCU
TC22x
AURIX™
Outlet
CAN-Bus
Chassis
1) If the ECU is permanently supplied, you may need to add external protection against load dump 400 ms above 40 V.
2) Not AEC-Q100 qualified
System Benefits
„„ Integrated solution reduces the design outlay
„„ Pin-to-pin compatibility between the 12 and 24 V
PROFET™+ families
„„ Family concept with RDS(on) scalability reduces
the engineering outlay
„„ Protection functions, including SC, overload, OT and ESD
„„ Diagnostic functions, including open load, OT detection,
integrated OPAMP and current sense
„„ One-stop shop: supply, microcontrollers, actuators
and sensors
Suggested Products
Product
Description
AURIX™/XMC
32-bit high-performance microcontroller families (automotive/industrial)
PROFET™+ 24V
Smart high-side switches for 24 V applications
Network Transceivers
LIN and CAN transceivers
Hall Sensors
Magnetic speed sensors
Supply ICs
Linear voltage regulator
TLE6389
DC/DC converter (automotive)
www.infineon.com/cav-pneumatic
19
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endangering applications, including but not limited to
medical, nuclear, military, life critical or any other applications where a failure of the product or any consequences of
the use thereof can result in personal injury.
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