Power Modulation Investigation for High Temperature (175-200 degrees Celcius) Automotive Application

Hybrid electric vehicles were re-introduced in the late 1990s after a century dominated by purely internal combustion powered engines[1]. Automotive players, such as GM, Ford, DaimlerChrysler, Honda, and Toyota, together with major energy producers, such as BPAmoco, were the major force in the development of hybrid electric vehicles. Most notable was the development by Toyota of its Prius, which was launched in Japan in 1997 and worldwide in 2001. The shift to hybrids was driven by the fact that the sheer volume of vehicles on the road had begun to tax the ability of the environment to withstand the pollution of the internal combustion engine and the ability of the fossil fuel industry to produce a sufficient amount of refined gasoline. In addition, the number of vehicles was anticipated to rise exponentially with the increasing affluence of China and India. Over the last fifteen years, major advances have been made in all the technologies essential to hybrid vehicle success, including batteries, motors, power control and conditioning electronics, regenerative braking, and power sources, including fuel cells. Current hybrid electric vehicles are gasoline internal combustion--electric motor hybrids. These hybrid electric vehicles range from micro-hybrids, where a stop/start system cuts the engine while the vehicle is stopped, and mild hybrids where the stop/start system is supplemented by regenerative braking and power assist, to full hybrids where the combustion motor is optimized for electric power production, and there is full electric drive and full regenerative braking. PSA Peugeot Citroen estimates the increased energy efficiency will range from 3-6% for the micro-hybrids to 15-25% for the full hybrids.[2] Gasoline-electric hybrids are preferred in US because they permit long distance travel with low emissions and high gasoline mileage, while still using the existing refueling infrastructure. One of the most critical areas in which technology has been advancing has been the development of electronics that can operate in the high temperature environments present in hybrid vehicles. The temperatures under the hood for a gasoline-electric hybrid vehicle are comparable to those for traditional internal combustion engines. This is known to be a difficult environment with respect to commercial-grade electronics, as there are surface and ambient temperatures ranging from 125 C to 175 C. In addition, some hybrid drive electronics are placed in even harsher environments, such as on or near the brakes, where temperatures can reach 250 C. Furthermore, number of temperature cycles experienced by electronics in a hybrid vehicle is different from that experienced in a traditional vehicle. A traditional internal combustion vehicle will have the engine running for longer periods, whereas a mild or micro-hybrid engine will experience many more starts and stops.[3] This means that hybrid automotive electronics will undergo more cycles of a potential wider temperature cycle than standard automotive electronics, which in turn see temperature cycles of 2 to 3 times the magnitude of the {Delta}T = 50 C-75 C experienced by commercial-grade electronics. This study will discuss the effects of these harsh environments on the failure mechanisms and ultimate reliability of electronic systems developed for gasoline-electric hybrid vehicles. In addition, it will suggest technologies and components that can reasonably be expected to perform well in these environments. Finally, it will suggest areas where further research is needed or desirable. Areas for further research will be highlighted in bold, italic type. It should be noted that the first area where further research is desirable is in developing a clearer understanding of the actual hybrid automotive electronics environment and how to simulate it through accelerated testing, thus: Developing specific mission profiles and accelerated testing protocols for the underhood environment for hybrid cars, as has previously been done for gasoline-powered vehicles, is an important area for further study