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 Ask Infineon. 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