Developed by Scienlab's electronic systems, a new traction inverter is not only compact, lightweight, but also has a high power density and can be flexibly adapted to a wide range of needs, making it ideal for a growing range of electric vehicles. New inverters can be developed with CeraLinkTM capacitors used in DC links. As more and more vehicles are equipped with energy-efficient and zero-emission drivers, the development trend of electric vehicles has finally won the attention of the market. In addition to cars, electric vehicles include small utility vehicles used in municipal services, electronic forklifts, construction, agricultural and industrial trucks, and vehicles in automated factory floors. Therefore, there is an increasing demand for compact, lightweight, and cost effective drives for use in these vehicles. Innovative Inverter Design To meet these needs, the power electronics design expert Scienlab Electronic System (Bochum, Germany) designed and developed a compact inverter (2 dm3). The inverter is rated at 40 kW and supports operating voltages from 290 V DC to 420 V DC, making it suitable for a wide range of applications. The hardware and software architecture of the inverter has a dynamic output current range for dynamic vehicle performance. The new Scienlab traction inverter is designed with four main functional units, namely control circuitry, drives, power electronics, and a rugged enclosure and interface. The inverter has an IGBT module that fully controls the three-phase bridge circuit (B6C), and its built-in DC link uses the innovative CeraLink capacitor, a key component of the new design (Figure 1). The modular design allows the inverter to be flexibly adapted to the user's specific current and power requirements. For example, a high-power IGBT module can be used to drive a PCB with a few changes, and the self-contained DC link board can be easily extended by simply increasing the number of CeraLink capacitors without any changes to the control circuitry. In addition, the inverter software for automotive applications, placed inside the controller is created by the tool chain, and its adaptive development process can adapt to the user's special software requirements without modifying the software architecture. Figure 1: Block diagram of a Scienlab inverter with CeraLink capacitors
There are 36 CeraLink capacitors connected in parallel in the DC link.
Inverter Requirements In order to make the inverter suitable for automotive electric applications, the new design must only use automotive grade components. In addition, a very high power density must be provided to ensure compact and lightweight. To meet these needs, Scienlab uses a water-cooled IGBT (power semiconductor chip with a small surface area) while optimizing the configuration of the controller and driver board to save space. However, Scienlab will focus on the volume and performance of the DC link, the largest component of the inverter. Compact and flexible DC link with CeraLink capacitors For DC links, Scienlab chose TDK Group's CeraLink capacitors with a very high capacitance density of up to 5.5μF/cm3 (Figure 2). “CeraLink offers the best combination of capacitance density and ripple current capability compared to other capacitor technologies,†explains Christoph Doerlemann, General Manager of Scienlab. Compact packaging is achieved without sacrificing any performance of the DC link. “This is the difference between our traction inverters and other inverters,†he said. Figure 2: Capacitance Density and Ripple Current Capability of Unit Capacitor Volume
For applications that require high capacitance density and high ripple current capability, CeraLink capacitor technology is the best choice.
Unlike traditional ceramic capacitors, these new capacitors are based on the ceramic material PLZT (lead zirconate titanate), whose capacitance value is maximized at the applied voltage and even increases proportionally with the proportion of the ripple voltage. Compared to traditional capacitor designs, the new design of the compact CeraLink capacitor reduces the size of the DC link by a factor of three to four. This series of capacitors is professionally designed to operate over the -40 to +125 °C temperature range and can withstand even transient high temperatures up to 150 °C. The use of multiple discrete capacitors not only increases the flexibility of component placement, but also maximizes the surface area and heat dissipation of the capacitor. Therefore, passive cooling technology can be used even at high ambient temperatures. Eliminating ESR and ESLScienlab's further design goal is to eliminate ESR and ESL for DC links. “With CraLink's very low ESL of only 2.5 nH, the overshoot and current during IGBT switching can be significantly reduced, significantly improving the system performance of the inverter,†Doerlemann points out. In addition, Scienlab parallels the capacitors on a specially developed multi-layer PCB so that the internal resistance is also low. The ESR value of only 1 mΩ at 1 MHz helps to significantly reduce the power loss of the DC link and the resulting heat. In fact, as the frequency increases and the temperature rises, the ESR decreases, allowing for efficient operation at temperatures up to 150 ° C and high switching frequencies.
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