SUCCESSEPCOS Capacitors

EPCOS Inc.
Capacitors GroupApril, 2012

EV / HV / E-Mobility
Battery charger system & Inverter
On Board and Off Board Assembly
Trend: Wireless Charging

DC/DC Converter Filtering
DC Link
E-Mobility
DC Link
Braking Energy Recuperation
EPCOS Capacitors

CAPS • 06/12 • 2Hybrid / Electric Vehicle

EPCOS Capacitors

CAPS • 06/12 • 3

Battery Electric Vehicle (BEV) Block Diagram

Wired &WirelessCharger

1.
2.
3.

The battery charger performs three electronic functions.
Enhanced phase adjustments made to the wall socket’s alternating current.
The voltage is rectified to direct current (DC) voltage.
The final step is to up-convert the household voltage; enough to charge an EV with 40-mile all-electric range

EPCOS Capacitors

CAPS • 06/12 • 4

Battery Charger Circuit Diagram

1. Filter Capacitor – EMI protection - X & Y caps
2. DC Link Capacitor – Alu Snap-in, MKP Cap
3. Output Capacitor – MKT and MKP caps

EPCOS Capacitors

CAPS • 06/12 • 5

Battery Charger Circuit Diagram

1. Filter Capacitor - Due to the connection to the net for the external charging for thebattery and the high currents we are facing inside the car, on some positions real X2 andY2 capacitors with the standard safety approvals (ENEC and UL) are necessary.

EPCOS Capacitors

CAPS • 06/12 • 6

Filter Capacitor for Charging / Plug In System
Technical requirements:
Operation Temp:
Capacitance range:
Voltage rate:
Standard Safety
Approvals

105C
1nF - 45µF
300VACUL / ENECEPCOS solution:

EMI X2 /Y2 Cap
AEC-Q200
Film
Capacitor
Boxed
Cap. range(µF)
voltagerange (VAC)

EPCOS Capacitors

MKP
X2
B3292X
0.01 45µF

MKT
X2
B3293X
0.047 10µF

305

305
300
Heavy Duty
85/85/1000/240MKPY2B3202X
1nF 1µF

Recent test results:
Up to 2000Hrs!!!

CAPS • 06/12 • 7

DC Film Capacitors
Heavy Duty X2 Series, B3293x
EPCOS has designed and developed a new series of MKT film capacitors for AC applications (B3293x - Heavy
Duty X2 series).
This series offers high durability and very low capacitance drift even after being subjected to tests of 1000-hours
at 85ºC / 85%RH and 240Vac. Their maximum capacitance change is expected to be less than 10%. The B3293#series cover a capacitance range from 0.047µF to 10µF and are designed for a nominal voltage of 305 Vac. Theirmaximum operating temperature is 105º C. In addition, capacitance values up to and including 2.2µF are safety
certified as X2’s capacitors.
Some features for the Heavy Duty Design:• Internal series connection
Voltage per connection is divided by half so that avoiding the undesirable effects of AC voltage (i.e. partial discharges).

• Polyester (PET) as dielectric material
Due to its higher dielectric constant than polypropylene (PP), it allows a higher density of capacitance per volume,
reaching smaller sizes. Better resistance to higher temperatures (i.e. 125º C)• Electrode metallization
No use of Zn material, for high resistance to humidity.
EPCOS Capacitors

CAPS • 06/12 • 8

Battery Charger Circuit Diagram

2. DC Link Capacitors - The main objective is energy storage. A high energy and high capacitanceby voltage product that can withstand high temperatures and offer long life.

EPCOS Capacitors

CAPS • 06/12 • 9

DC Link Capacitor – Film Capacitors
Techical requirements:
OperationTemperature: 105C
Capacitance range:
Up to 480µF
Voltage rate:
Up to 1300VDC
High Reliability
EPCOS solution:
Capacitor

MKP
DC Link
1.5 - 480µF
Cap. range(µF)(std)
voltage range (VDC) 450-1300

EPCOS Capacitors

CAPS • 06/12 • 10

DC Link Capacitors
High Density DC Link B3277x series

C (µF)
Lead Spaces (mm): 37.5 ~ 52.5
Climatic Category: 40/100/56
UN / UOP

450V

10 µF
12 µF
15 µF
20 µF
25 µF
30 µF
35 µF
40 µF
50 µF
60 µF
70 µF
100 µF110 µFEPCOS Capacitors

700V

900V

1100V

450 Vdc

575 Vdc

NEW!!!

800 Vdc

900 Vdc

1100 Vdc 1300 Vdc

14254060758090100110120130140170180210250270320360480

CAPS • 06/12 • 11

Low-Profile Capacitors, B32*6T series

NEW!!!

 Low-profile with heights of only 15 or 19 mm
 Good self-healing properties
 High reliability
 Long useful life Very high mechanical resistance to vibrations and shocks
Product Series:
B3722
Dielectric:
MKP
Lead Spaces:
37.5 - 52.5mm
Climatic Catergory: 40/85/56
CV450575
913141720
17222530
4055

EPCOS Capacitors

8009001100

1300

CAPS • 06/12 • 12

DC Link Capacitor – ALU Capacitor
Technical requirements:
Operation temperature:Service Life
Ripple capability:
Capacitance range:
Voltage:

105C
15 years / 120,000 km
8Arms, 60C, 10kHz
1,500µF - 2,000µF
450VdcEPCOS solution

TypeSnap-inSeries

B43540 / B43508

Operation Tempup to 105C

Cap. range (µF)
voltage (VDC)

100 - 470µF
450V

Qualified according

AEC Q200 (*)(*) in qualification - Jun. 2012

Samples available

EPCOS Capacitors

CAPS • 06/12 • 13

Battery Charger Circuit Diagram

3. Output Capacitor - Capability to withstand over-voltages, and transients coming from the mains.
Capability to withstand high current pulses together with a high frequency harmonics
International approvals such as UL/IEC are not always required for this position.

EPCOS Capacitors

CAPS • 06/12 • 14

Output Filter Capacitor
Technical requirements:
Operation Temperature: 105C
Capacitance Range:
0.47 - 220µF
Voltage rate:
63-450VDC
Ripple Capability:
20A, 70C, 10KHz
Useful life:
100KHrs/70degC
EPCOS solution:

Film Capacitors
Film Capacitor
Boxed
Cap. range (µF)
Voltage range

EPCOS Capacitors

MKT
B32524A
B32526A
4.7-220µF
63-250VDC

MKPAC Filter
B3279x0.82-75µF
250-400VAC

MKP
DC LinkB3277x
1.5 - 480µF
450-1300 VDCCAPS • 06/12 • 15

Trend: Wireless Charging

Wireless power transfer technology is not a new technology;
however, recent developments have allowed it
to become more practical, and recent interest in the consumer market hasbrought it to the center of attention

Wireless charging, also known as inductive charging, removes the need torun a cable from the device
to the charging point and instead sends energy between two flat plates –one in the device andone on (or in) the ground below it – which charges the battery.

EPCOS Capacitors

CAPS • 06/12 • 16

Trend: Wireless Charging

VVacBlock Diagram
Charger BaseV

Battery
SensorController

User Display

V_bat

Target Device

Battery
fullPowerabsorbed

EPCOS Capacitors

VChargingController

Inductive
PickupDevice PowerRegulator

Chargedata

DevicestatusInductive
Technology

ChargeenablePower_out

PowerTransmission
Coils

Power Supply

V

Devicepresent

DeviceSensing

V_Charge

Battery
ChargeController

V_Charge

CAPS • 06/12 • 17

Battery Electric Vehicle (BEV) Block Diagram

The DC/DC converter is responsible for converting High DC Voltage
from batteries to Low DC Voltage on general applications

EPCOS Capacitors

CAPS • 06/12 • 18

DC/DC converter – Filtering
Since in most of the hybrid drives there is no starter and no alternator, the DC/DC converter
has to be bi-directional.

ElectricmotorVAC

AC / DCConverter

VHB

HVbattery

VHB

DC / DC 12VConverter

Board
net 12V

The voltage level in the hybrid circuit is at the level of 200 – 400 Vdc.
DC/DC converter for hybrid / electric vehicle• Used for the conversion of the battery voltage of 14V to a higher voltage level (42V or evenmore) and vice versa. (Typical application: Power steering)• The film capacitor is used as an input and output filter

Capacitor
HighvoltagesideCapacitor

14 V2EPCOS Capacitors

CAPS • 06/12 • 19

DC/DC converter - Filtering
Requirements:
 Very high reliability
 Vibration resistance Excellent current handling capability
 Low ESR

Series

B3252x

B3277xTypeMKTMKPVR (Vdc)

63

100

250

400

450

CR (µF)
51022
33
50
68
100

Solutions from Epcos
MKT B3252x and MKP B3277x
 different lead configurations for vibration
resistance:- normal 2-pin- 4-pin or multi-pin- flat terminals
 low ESR at high frequencies
 high current handling capability

110150200220

2EPCOS Capacitors

CAPS • 06/12 • 20

Battery Electric Vehicle (BEV) Block Diagram

The DC Link is responsible for supplying energy or smoothing voltage
ripple during the conversion of DC High voltage for the motors.

EPCOS Capacitors

CAPS • 06/12 • 21

DC Link Capacitors for Automotive Applications
Customer Demands
 Compact Size
 Higher Temperature Ratings (105 ambient) Higher Currents
 Customized terminals
 Lower ESLSpecifications
 Capacitance: 300 to 1000 uF
 Voltage Rating:450 to 600 V DC
 Ripple Current: 112 to 240 A

EPCOS Capacitors

CAPS • 06/12 • 22

DC/DC Converter - DC Link Capacitor – ALU Capacitor
Function: the inverter controls the energy flow between electric motor and thehybrid battery while the DC/DC converter couples the hybrid battery to the overall
power supply system.
Requirements:
 Voltage bank – 160V
 High reliability up toHigh current capability – 10A / cap Vibration resistance up to 40g
 Excellent current handling capability
 Low ESREPCOS solution

EPCOS Capacitors

TypeSeries

Axial / Soldering StarOperation Temp

B43693 / B43793
up to 105C

Cap. range (µF)

100 - 470µF

voltage (V )160 - 200V

Qualified according

AEC Q200CAPS • 06/12 • 23

E-Mobility – New Application• Hybrid DC-Link with MOSFET Technology – 110V operating voltage athigh ripple current



Axial-lead capacitor in Soldering star mechanical configuration

e.g. 21 x 49 mm, 400 µF, 160 V with max. 9 Arms at 125°C

EPCOS Capacitors

CAPS • 06/12 • 24

E-Mobility – New Application• Energy recuperation via braking system, high ripple current and vibration
resistance >40 g
The cooperative regenerative braking system ensures that asmuch braking energy as possible is recuperated
and stored as electrical energy.
To do this, the generator is used to slow the vehicle down. As
soon as the braking requirements exceed thebraking capacity of the generator, the classic wheel brakes
are applied.

Axial-lead capacitor

e.g. 20 x 29 mm, 500 µF, 63 V with max. 9.5 Arms at 125°C

EPCOS Capacitors

CAPS • 06/12 • 25

Comfort Electronics - EMC Protection

Smart Parking

All these motors are causing radiofrequency emissions!!!
EPCOS Capacitors

2CAPS • 06/12 • 26

Comfort Electronics - EMC Protection
To ensure successful operation of all electronic modules in the car, theseinterferences must be caught directly at each motor
Requirements:
 thermal stability up to 125°Ceven up to 150°C for special applications like the waterpump
 high pulse handling capability according ISO 7631
 high reliability
 flexible mounting possibilities
Typical applications:Power windows
Windscreen wipers
Power seats
Sun / Moon roof
2EPCOS Capacitors

CAPS • 06/12 • 27

Comfort Electronics - EMC Protection
MKT boxed B3252x series
 Customized mechanicalconfiguration availableBent leadsLonger leads
Lead-frames

Leadspace

5.0 mm

7.5 mm

10.0 mm15.0 mm

TypeB32529

B32520

B32521

B32522

VR (Vdc)

63100

63100

63

100

63

100

Vrms (Vac)

40

63

40

63

40

63

40

63

CR (µF)
0.1
0.22
0.33
0.47

 AEC Q200 qualified

0,68
1.0
1.5
2.2
3.3
4.7
6.8
10.02

EPCOS Capacitors

CAPS • 06/12 • 28

Why TDK-EPC Capacitors?
 Long-standing experiencein developing reliable Capacitors
for Automotive applications.

SUCCESSCapacitor Lane High end product technologies
with long life & high ripple capability
 ALU Cap with vibration strength up to 40g
 Wide voltage range from 25V up to 1kV
 Specialist for customized solutions
 Local resource able to provide strong
technical support to customers‘ engineers

EPCOS Capacitors

CAPS • 06/12 • 29