EPCOS and Infineon Technologies jointly developed two new reference designs for hybrid and electric vehicle converters using EPCOS space-saving PCCTM solutions as DC link capacitors.
Infineon Technologies has developed two reference designs for IGBT converters for hybrid and all-electric drive in automotive electronics: HybridPACKTM1 for light hybrid electric drive and HybridPACKTM2 for full power and full hybrid Power drive.
The HybridPACK1 outputs up to 20 kW to support the internal combustion engine. Typically, the combined starting generator is located between the engine and the driveline and is directly connected to the shaft. It supports the internal combustion engine and increases torque, especially at acceleration. Some design concepts make electric drives dedicated to short distances.
Infineon Technologies offers HybridPACK2 for high power, including pure electric traction. Its output is up to 90 kW (Figure 1). Figure 1: Hybrid PACK2 Evaluation Kit with PCC
Infineon Technologies' HybridPACK evaluation kit can be used to develop EV drives up to 90 kW. In addition to controllers and software, it also includes PCC DC link capacitors from EPCOS.
Two types of evaluation kits provided by Infineon include controllers, software and DC link capacitors. They are based on accepted PCC technology. The following table shows the key technical data of the PCC.
EPCOS has successfully developed PCC technology for several years, especially compact DC link capacitors for hybrid technology or inverters. A particular advantage of this technology is the compact size of the capacitors. Traditional winding techniques produce regular or flat round cores. The situation for PCC is different: Stack winding technology is used. The polygon winder creates a perfectly flat, rectangular, and crease-free capacitor core, so the resulting capacitor has a volume fill factor close to unity. Another advantage of this technology is its adaptability: its size can be varied in a very wide range so that it can optimally adapt to the design of the frequency converter. Electrical and mechanical terminals, bus bars, can also be ideally matched to system requirements. This allows the PCC to be mounted directly on the IGBT module. On the one hand, this can greatly reduce assembly costs. On the other hand, other DC link solutions do not require a separate circuit board. Fig. 2: EPCOS hybrid drive PCC
In addition to a compact case size and a volume fill factor of approximately 1, the PCC also has bus bars that precisely match the IGBT module.
Especially for hybrid drives, EPCOS has also developed a PCC that can be housed in a ring-shaped structure in the housing surrounding the starter generator (Figure 3). Figure 3: Ring PCC
In this configuration, the PCC is mounted in a ring shape directly around the starter generator.
The short terminal connection and the internal structure of the capacitor ensure a very low inductance design. Depending on the capacitor design, the inductance can be only a few nH. This is especially important for converters with steep switching edges, which can avoid excessive voltages. In general, other protection circuits of the IGBT with snubber capacitor can be dispensed with. The high peak current capability of the capacitor is equally important. Especially in the case of frequent stop-and-go cycles in urban traffic, the peak current can reach several times the rated current. DC link capacitors must provide this current over the entire service life without causing damage. Figure 4 shows a typical drive cycle of 1800 seconds. The average current during the current service life is slightly higher than 100 A. Figure 4: DC link load diagram
The short-term peak current is about 325 A. The new generation of PCC products can withstand peak currents of 1200 to 2000 A without causing damage.
PCC has an expected service life of 15,000 hours and an upper continuous operating temperature of 110°C (short-term up to 125°C), especially for automotive electronics. This type also provides excellent safety and reliability: These capacitors are self-healing, meaning that they will not short-circuit or cause damage to the capacitors when the film is overdriven. The fact that the capacitors are not filled with flammable or acidic liquids is crucial in the event of an accident. All these factors make PCC an advanced and ideal DC link solution for converters for electric vehicles and compact inverters in the field of industrial electronics. Table: PCC Technical Data for HybridPACK 5
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