The TDK Group and Infineon Technologies jointly developed a xEV inverter. The new inverter combines the advantages of Infineon's IGBT module, EPCOS and TDK passive components, and is perfectly matched to increase the efficiency of the inverter to more than 98% in a power range of 10 to 150 kW. The new Infineon HybridPACKTM IGBT driver module has a compact structure and high efficiency, which can meet the core requirements of electric vehicle applications. The FS820R08A6P2B has an operating current of up to 820 A, an absorption voltage of 750 V and is equipped with pin-shaped heat sink fins for coolant. These modules can achieve up to 150 kW of drive power output. If the power is small, the FS660R08A6P2FB with a flat substrate can be used as an alternative solution. This IGBT module has the same electrical characteristics, but its maximum current is only 660 A. For xEV and industrial applications, the HybridPACKTM drive series offers excellent scalability for the power level of the inverter. The product family also contains different module frames, including the load terminal (FS820R08A6P2) solder contact frame and the long motor terminal (FS820R08A6P2LB) frame for simplified current Sensors. All modules of the R08A6P2 series are based on Infineon's latest generation of EDT2-IGBT chips. These chips are designed for applications with a plating temperature of up to 175°C in switch mode. The rugged chipset prevents short circuits and ensures high reliability even under the harshest conditions. In practical applications, the efficiency of the R08A6P2 series can be as high as 98% (see Figure 1). The module is optimized for switching frequencies in the range of 6 to 10 kHz.
Figure 1: Converter losses measured using an evaluation kit when the switching frequency is 8 kHz. When the power range is 10 to 150 kW, the maximum efficiency exceeds 98% (cos IV = 0.85 when the operating voltage is 450 V). This result effectively improves the power range of plug-in and hybrid electric vehicles.
The wide spacing between the connection points of these modules provides excellent insulation performance and minimizes leakage currents, ie the module is also suitable for high voltage applications in the future. Figure 2 shows the complete inverter module, which includes a HybridPACK module with a cooling plate, controller, and driver board, and an EPCOS PCC capacitor for DC link.
Fig. 2: Complete motor inverter with power output up to 150 kW. The most important passive component is the DC link capacitor, EPCOS PCC capacitor. The entire design module can be measured using the evaluation kit.
Compact solution for DC link This design mainly considers two types of EPCOS PCC capacitors, these capacitors are also suitable for other HybridPACK modules. Among them, the B25655P5507K051 adopts a laminated winding structure with a working voltage of 500 V DC and a capacity of 500 μF and can withstand continuous currents of up to 160 A. The great advantage of laminated winding technology is that it can achieve a high volume fill factor close to 1. The size of this capacitor is 154 mm x 72 mm x 50 mm. The second model (B25655P5407K1512) uses a low-cost, flat winding structure. Due to its low volume fill factor, the maximum continuous operating current is only 140A and the capacitance is 400 μF for the same size. During the design process, it must be ensured that the DC link capacitors remain fully cooled at the maximum current load. The low equivalent series inductance (ESL) and equivalent series resistance (ESR) values ​​of DC link capacitors are critical to the success or failure of an inverter design. When the IGBT is opened, only the equivalent series inductance is low enough to eliminate or minimize voltage peaks and oscillations. The above-mentioned PCC capacitor has an equivalent series inductance of only 15 nH, while the equivalent series resistance of the energy consumed is only 0.5 mΩ or 0.7 mΩ, respectively. Since the six terminals of the inverter bus bar exactly match the terminals of the HybridPACK module (see Figure 3), the equivalent series inductance and the equivalent series resistance of the inverter are quite low. If the bus bar is improved in the future, the equivalent series inductance of the inverter will be less than 10 nH, while the equivalent series resistance will be less than 0.5 mΩ.
Figure 3: EPCOS PCC capacitor busbars have six large terminals, ensuring that the equivalent series inductance and equivalent series resistance are minimized.
The above capacitor production line fully meets the requirements of automotive products and ensures the highest reliability. Special attention must be paid to the welding of its internal bus bars, since the quality of the welding directly determines the current carrying capacity and power consumption of the capacitors. In addition to high reliability, EPCOS PCC capacitors have excellent EMC performance and can achieve excellent noise suppression in the FM frequency band around 100 MHz. Galvanic Isolation - Basic Characteristics of Automotive Electronics The task of the driver board is to provide three high and three low threshold IGBTs to provide the necessary switching signals at the gate. It must be ensured that the galvanic isolation between the driver circuit and the IGBT is maintained to prevent the breakdown of the power supply voltage to the driver board and cause insulation breakdown. For this purpose, a gate drive transformer is used for the key components. Figure 4 shows an application circuit that provides an insulated IGBT driver.
Figure 4: The task of the gate driver transformer is to ensure reliable electrical isolation between the high and low side.
This reference design uses six B78307A2276A003 (P100403) EPCOS gate drive transformers. These transformers ensure that the insulation voltage of the inverter can be as high as 2.5kV (1 minute, 50Hz). The turns ratio of the transformer is 1:1.08 and the inductance is 100 μH. Despite the high dielectric strength, the size of the transformer is only 11.7 mm x 13.5 mm x 11.35 mm. In addition, the leakage current path between the primary side and the secondary side of the transformer is only 6 mm, making it ideal for converters with a continuous operating voltage of 500 V. The anti-interference logic control controller board summarizes the control logic of the entire inverter. Its core is the Infineon 32-bit TC277 microcontroller from the AURIXTM automotive series. To ensure trouble-free logic operation, the interface uses the TDK ACT45B-101-2P-TL003 CAN bus common mode choke. When the frequency is 10 MHz, the common mode impedance of these chokes can reach 5.8 kΩ, which can effectively ensure that the data transmission is not disturbed. The choke coil meets the AEC-Q200 standard and measures only 4.5 mm x 3.2 mm x 2.8 mm. It is currently the smallest choke coil in the world. In addition TDK MMZ1608R600AT beads can also effectively suppress the signal cable noise.
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