Most new electronic systems on conventional power vehicles (except active safety, autonomous driving and infotainment systems) can be used to help achieve greater energy savings, such as through direct injection technology, start-stop systems and body BLDC Motor drive and other car sound and chassis electronic mode. The CO2 emission regulations (limits of 95 g/km) are driving the urgent need to improve fuel efficiency and car electrification levels, especially in busy urban areas and metropolitan areas, where significant reductions in CO2 and particulate matter are needed to maintain air quality. .
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The following factors represent and influence the future trends and successful development of electric vehicles (EVs):
â—Battery technology – energy density, size and price
â— mileage and efficiency
â—Charging performance, time and infrastructure construction
â—Price, incentive and tax policy
â— Reliability and maintenance costs
â—Security
When a car crashes, the electronic system needs to be disconnected from all energy storage components (such as batteries, capacitors, and inductive components). Direct contact with high voltages can cause serious bodily harm to drivers, passengers and emergency personnel. In order to release energy such as these energy storage elements, a resistive virtual load needs to be connected immediately.
Intelligent energy management is important to ensure that all safety-related applications, such as braking, steering, wipers, lighting, and passive safety systems, work properly during long-distance driving. In addition to the safest electronic systems with the highest priority in terms of power consumption, comfort electronics systems also need to be considered. Air conditioning in summer, as well as cabin heating and window de-fogging in winter are the functions and equipment that modern cars must have. A huge challenge in the design of electric vehicles is to reduce the power consumption of these high power loads.
The next most important task is to provide enough charging stations in the area of ​​the car (especially when parking). Fast charging is very important to the end user because usually no user will be willing to wait for more than two hours for full charge. Modern electric vehicles must be fully charged during work, business visits or shopping. In addition, incentives are essential, such as discounts, alternative energy sources and reduced parking fees.
An essential component of electric vehicles is the battery charging system. Its main function is to convert alternating current (AC) to direct current (DC), perform power factor correction (PFC), and match the charging system of the battery system.
There are two main solutions for battery charging and their respective advantages:
1. On-board: single-phase and three-phase AC charging from the grid
- Easy to connect to the grid.
- No large charging infrastructure required.
2. Off-board: ultra-fast and large DC point off-board charging
- Short time, high power, fast charge performance
- Charging infrastructure with universal high power DC charger
A key part of the on-board charging system is the AC/DC converter fully integrated into the body network. It connects the car to the AC grid and converts the AC to DC. Because of the high voltage application, it is very important to ensure safety and to comply with the appropriate standards when applied. All electronic systems need to meet these automotive-grade quality standards.
Another option is to use an off-board DC/DC charger to input high-voltage direct current to an electric vehicle instead of an alternating current. This solution can provide very high-power charging function, does not require a car charger, can help reduce the weight of the car charger to the body and save a lot of space, but still responsible for the battery charging phase control and off-board charging Machine communication. This keeps the car away from the AC voltage and does not have to worry about the safety hazards it poses. It also reduces the instantaneous spike voltage that the ECU can withstand. Industrial chargers with a maximum power of 50 kW are available on the market and will be gradually invested in transportation infrastructure, such as parking areas and bus stops.
The third method is the contactless inductive charging that is now emerging. The goal is to provide an almost ubiquitous charging facility to reduce charging time and provide near-instant charging services.
Both the semiconductor active and passive device industries need to design new components to reduce the cost of electric vehicle controllers and actuators. The mechatronics + high voltage drive solution is a key part of optimizing reliability and increasing efficiency. Multiphase converters and inverters are the areas of application that are of particular interest. All major component manufacturers are developing cost-effective new components and technologies to meet the needs of high-power and high-energy applications.
The main components in electric vehicles are:
â— IGBT module for motor drive and inverter
â—High voltage MOSFET
â—High current filter inductor
â— Planar transformer
â—Photocoupler
â—Solid state relay
â—High voltage divider resistor
â—PTC thermistor current limiter
â—High voltage diode
â—Rectifier bridge module
Passive components require more space and have higher costs. Its design is also more critical than the design of semiconductor active component modules. The new circuit topology is dedicated to increasing the switching frequency of the circuit and reducing the size of passive components such as transformers, filters and energy storage components. These topologies include DC bus filter film capacitors that can be used, aluminum capacitors for DC bus or buffering, and sense resistors for high voltage and large electrical detection. Planar transformers have a unique solution for high switching frequency circuits and provide optimum efficiency in high voltage DC/DC converter applications.
There are two types of electronic drives for electric vehicles:
â—High voltage application (150VDC-550VDC battery line)
â— Low voltage application (12 V load)
DC/DC buck converters for switching from high-voltage lithium-ion batteries to 12 V outputs are primarily suitable for low-power loads of 100 W and below. The overall efficiency of these converters needs to be as high as possible.
One of the biggest challenges facing electric vehicles is ensuring the efficiency of motor drives driven by high voltage semiconductors. In addition, personal safety is also an important concern. To avoid sparking in high-voltage switches, you need to use a virtual energy resistor to discharge the battery and other components, which can quickly eliminate energy to avoid a fire. Emergency disconnection of the battery connection is another area that needs to be optimized and requires a redesign of the current large and heavy solution.
Like regular cars, system designers of electric vehicles want to reduce the number of components. An example of achieving this goal is a new series of voltage divider resistors with excellent accuracy characteristics at 3 kV power levels and below. These surface mount high voltage divider resistors can replace 20-40 single resistors for conventional applications. They are currently used as floating point dividers to detect voltage stability of circuit board systems and to support voltage drop regulation to increase efficiency.
The various parts of electric vehicles are accompanied by their unique challenges. For example, motor drives for air conditioner compressors require very efficient isolated DC/DC converters. In the design of this application, discrete components with extremely low heights play an important role.
When the voltage is above 30VAC and above 60VDC, it is necessary to strengthen the protection against electric shock of the human body. Low voltage (galvanic isolation between 12 V digital/analog parts and high voltage terminals is essential).
The following areas are subject to standardization:
â—Energy storage system
â—Automotive technology (power electronics and transmission systems)
â— Product and operational safety (electrical safety and functional safety)
â—Electromagnetic compatibility (EMC)
â— plug-in charger (car and off-board charging)
Electric vehicles currently support short-distance travel (average 50 km per day, up to 100 km), but they are not able to meet the demand level for long-distance travel (greater than 150 km). Since the current price of electric vehicle end users is higher than that of conventional cars, investing in charging infrastructure and developing alternative energy sources (mainly by government power and incentives) can promote the large-scale development of pure electric vehicles (BEVs).
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