Electric Vehicle Inverters

Renesas Electronics Corporation (Milpitas, CA) announced the development of a new generation of Si-IGBTs (Silicon Insulated Gate Bipolar Transistors) which will be offered in a small footprint. Aimed at next-generation EVs inverters, AE5-generation IGBTs will be mass produced starting in the first half of 2023 on Renesas’ 200- and 300-mm wafer lines. The silicon-based AE5 process for IGBTs achieve a 10 percent reduction in power losses compared to the current-generation AE4 products, a power savings that will help EV developers save battery power and increase driving range. In addition, the new products are approximately 10 percent smaller while maintaining high robustness. The new devices achieve high performance for IGBTs by optimally balancing low power loss and robustness tradeoffs. Moreover, the new IGBTs significantly improve performance and safety as modules by minimizing parameter variations among the IGBTs and providing stability when operating IGBTs in parallel.

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Battery Interconnect System

Interplex (Tustin, CA) has further strengthened its product portfolio of interconnect solutions aimed at use in EV batteries. Having already proved popular with battery modules based on cylindrical and standard prismatic cells, the latest Cell-PLX™ version is specifically optimized for next-generation prismatic cells. Compliant with USCAR 2-6 automotive performance requirements, the platform provides the data transfer capabilities needed for constant monitoring of voltage and temperature parameters, with the ability to cover battery module voltages from 12V to above 800V. It can be adapted to suit any battery shape or size, with battery modules consisting of thousands of cells being addressed. These interconnect solutions can handle current densities up to 15A/mm2. They will continue to function even when exposed to intense vibrations. They can be supplied with a choice of either aluminum or copper current collecting layers, each accompanied by a UL 94 rated dielectric insulation layer.

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Safe Packaging and Transport Case

The ZARGES (Charlotte, SC) BatterySafe Intermediate is a case for the safe packaging and transport of Lithium-ion batteries. The ZARGES solution is comprised of an aluminum case with a custom lining, which contains an intumescent glass fiber material that suppresses ignition and extinguishes flames. The BatterySafe Intermediate offers all the available features of our standard K470 cases, including secure latches, stacking corners, three fully welded aluminum profile frames, and easy loading and unloading. The cases are appropriate for a variety of uses including for defense contractors standardizing battery management, vehicle battery development, medical equipment, and drones. U.N. Certification is available on select cases for domestic and international shipping, including UN3090, UN3091, UN3480, and UN3481. The case is suitable for 1– 1,500 Wh batteries (at 100 percent state of charge) and is outfitted with three separate cavities, each 17 x 5 x 5 cavities may be subdivided (x2, x3, x4, or more) with BatterySafe intumescent glass fiber pad. Custom configurations are available for higher Wh batteries.

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Silicon Nitride Bearing Balls

CoorsTek (Lakewood, CO) offers Cerbec® silicon nitride bearing balls that are an ideal combination of mechanical strength and electrical resistivity for usage in electric vehicle traction motors. Unlike steel, silicon nitride hybrid bearing assemblies provide strong electrical insulation to eliminate arcing without compromise to critical mechanical properties. Silicon nitride bearing balls are extremely smooth for low friction, tough enough to withstand shock loads, and very hard for rolling efficiency and durability. In electric vehicle motors, especially those designed as variable speed drives, shaft voltage occurs from leakage, induction, or capacitive coupling with the windings of the motor and can create arcing in the bearing assembly. Inherently electrically resistant, silicon nitride bearing balls prevent arcing caused by charge build up or high voltage. In addition to offering the right mix of mechanical properties and electrical insulation ideal for usage in EV motor shafts, Cerbec ® silicon nitride bearing balls require less lubrication, are corrosion resistant, and 58 percent lighter than steel alloys, which also increases the high-speed capability of hybrid bearing assemblies.

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Automotive Relays

CIT Relay & Switch (Rogers, MN) is offering an automotive relay with a blow-out magnet. In the automotive relay world, 12VDC and 24VDC systems have been the norm for over 50 years. With the world trending toward EVs there is a need for higher voltage DC switching. As DC voltages increase, so does the chance of developing what is called a standing arc, where the contacts open and the arc does not extinguish when the relay returns to the fully open position. This condition is very damaging to the contacts and can cause welding of the contacts and even melting of the relay. To combat this, a permanent magnet has been placed next to the contacts to pull on the arc to help it extinguish sooner. The A2K Series uses the blow-out magnet to help break the electric arc that is formed when the contacts of the relay are opening. With a large switching capacity up to 60 amps, the A2K series also offers resistor and diode options for coil suppression along with PCB Pin or Quick Connect terminals and is available with or without a mounting bracket.

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Regenerative DC Emulator

Keysight Technologies (Santa Rosa, CA) offers an enhanced Scienlab Regenerative DC Emulator (SL1800A Series), the next generation high power direct current (DC) emulator for EV fast charging applications that enables customers to achieve high-power DC charging test up to 270 kilowatts (kW) in a small footprint. Typical high-power DC test systems are large and occupy valuable lab floor space. These systems are also inefficient, requiring large amounts of energy to run the test system and to keep the lab space cool during high-power tests. When performing high-power DC fast charging tests, customers need a solution that combines the needed power requirements with communication tests and monitoring that is easy to set up and use. The Scienlab Regenerative DC Emulator enables customers to realistically emulate high-voltage, high-power EV batteries in charging test applications, such as high-power DC fast charging, when paired with Keysight’s SL1047A Scienlab Charging Discovery System. This solution can emulate EV batteries up to 1500 volts, up to 900 amperes, and can be paralleled to achieve up to megawatts (MW).

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Multicell Battery Monitoring

STMicroelectronics (Coppell, TX) L9963E Multicell Battery Monitoring & Balancing IC is a Li-ion battery monitoring and protecting chip for high-reliability automotive applications and energy storage systems. Up to 14 stacked battery cells can be monitored to meet the requirements of 48V and higher voltage systems. Each cell voltage is measured with high accuracy, as well as the current for the on-chip coulomb counting. The device can monitor up to seven NTCs. The information is transmitted through SPI communication or an isolated interface. Multiple L9963E can be connected in a daisy chain and communicate with one host processor via the transformer isolated interfaces, featuring high-speed, low EMI, long-distance, and reliable data transmission. Passive balancing with programmable channel selection is offered in both normal and low power mode (silent balance). The balancing can be terminated automatically based on internal timer interrupt. Nine GPIOs are integrated for external monitoring and control. The STMicroelectronics L9963E features a comprehensive set of fault detection and notification functions to meet the safety standard requirements.

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Pressure-Reducing Regulator

Emerson (St. Louis, MO) has launched a pressure-reducing regulator specially designed for use onboard commercial hydrogen fuel cell vehicles. The dual stage and patented active seal design of the TESCOM™ HV-3500 Hydrogen Onboard Regulator delivers steady pressure and constant hydrogen fuel supply to fuel cells in the full range of vehicle operating conditions, including acceleration, deceleration, stopping and idling. Stable pressure aids in extending fuel cell life and maximizing fuel usage. The reliable fuel pressure provided by the HV-3500 allows operators to drive farther without refueling and decreases the risk of over pressurization downstream, resulting in leakage, wasted fuel and possible emissions. The HV-3500 has been designed, engineered, and independently tested to ensure compliance with EC79 requirements for pressure regulators used in hydrogen vehicles. By boosting fuel cell efficiency and maximizing overall energy efficiency, the stable pressure the HV-3500 provides also reduces maintenance frequency. The regulator delivers positive high-pressure fuel shutoff of hydrogen in vehicles across varying road and operating conditions, increasing fuel cell durability.

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Modular Battery Energy Storage System

Developed by Advanced Battery Concepts (Clare, MI) “Box-Be” – a BOX of Bipolar Energy – is a modular Battery Energy Storage System. This system is powered by our Advanced BiPolar EverGreenSeal™ technology and is designed to meet the energy needs of today and future generations. The design of BOX-BE allows for easy and safe scalability while providing high power and energy for long-duration discharges. Its simple parallel connections enable seamless field installation. It supports a seamless expansion of energy storage capacity and charging duration with a self-contained, self-regulated DC battery pack. BOX-BE plug and play design allows for easy and simple connection to adjacent units. The non-flammable chemistry is incapable of thermal self-ignition, assuring safety and peace of mind over the lifetime of the system. BOX-BE units are recovered and nearly all components are processed and reused. Disassembly and recovery of parts consumes little energy and virtually no waste, making BOX-BE the ideal green energy storage technology for carbon footprint reduction.

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