High Power Inverters

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Green Energy Automotive

Industrial

AC ~ AC ~ AC/DC DC/AC Power Converter Inverter Power Source Load 2 3 6 7 2 7 4 5 5 0 1

Components

0 Common Mode 3 EMI Core 4 Boost Reactor 7 Current Sensor Choke Coil

Capacitors

Noise is classified according to the conduction mode into either Common Mode of Differential Mode

Differential Mode Common Mode

Differential Mode Common Mode Electronic Filter lay-out Attenuated with Suppressed by Chokes and Differential Mode is also known as “Normal” Mode. Inductors & X-capacitors Y-capacitors

AC Line Filters are choke coil products used to suppress both types of noise.

Common Mode Differential or Normal Mode 4 Pins 2 Pins

SCR HHB

Developed the Highest µ S18H

Features • Use of high performance SR18 material • High current (~50A) and high voltage (500V)

Advantages SCR-HB(S18H) • High impedance (greater than any other ferrite +35% common mode choke) -30% • Same performance in smaller size and less Conventional SCR(S15H) winding Conventional SC(10H) • Custom designs available

To ECU I/F Conventional

12V

Drive Circuit Motor

Existing magnetic circuit causing the interference Common Normal to outer field by leakage flux

New Design Hybrid

Conventional Design New Design

Common Mode Choke Differential Mode Hybrid Choke Choke x 2 Reduce Footprint & Save Space

3 in 1 ＋

Development of New Material (Ferrite)

New ferrite core with increased Tc and Bs has developed for Hybrid Line-Filter

• Wide range of supported applications – Attenuate high frequency noise and reduce radiation of EMI noise in DC applications – Available in three-phase (high current and high voltage variations) and standard DC EMI filtering

Function Reduce the harmonic components overlapped to the fundamental frequency.

Rated Voltages • 525 – 640+ Vac - Input • 330+ Vac - Output (Star Connection) • 440+ Vac - Output (Delta Connection) • > 690 Vac - Wind Generators

Demanded Life Expectancy • >10 years (100K Hours) – Currently at 60k (C4AF)

• Two derating equations exist:

1. Life Expectancy vs. Voltage:

8 LE = LN x (VN / V)

LE = Life expectancy at operating voltage (hours) LN = Life expectancy at nominal voltage (hours) VN = Nominal voltage Un (V) V = Operating voltage (V) Note: The above formula is valid within ± 20% of the nominal voltage.

2. Life Expectancy vs. Temperature:

LE = LTo x 2 (To – Ths ) / 7 LE = Life expectancy at operating temperature (hours) LTo = Life expectancy at 70°C (hours) To = Reference temperature (70°C) Ths = Hot spot case temperature (≤ 70°C)

Note: These equations can be used together

Feature Single Phase Three-Phase C44 & C20 C9T

Cost Higher Lower

Compactness No Yes

Cable Mounting Yes Yes C44P Bus Bar Mounting Yes No & C20

Parallel Yes No Connection (require a daisy-chain)

Irms/C Ratio Higher Lower

High AC Harmonic Yes No Component C9T

Feature Dry Impregnated High Temperature Yes No Capacitance Density Lower Higher Overpressure Protection No Yes

C44P C44A C4AF C20 C44E

• Impregnated Film is the best performing for AC filtering. • Dry Film is best suitable for high temperature AC filtering.

Application

Inverter Battery DC-DC Booster Motor

Bus Bar EMI Core ESD series Size Capability: 110 x 50 x 35mm / half piece Ferrite -40℃ ～ +155℃ 5HT Material Ferrite Permeability: 5000 250Amp 100KW Bus bar Common Mode Current: 10Amp CMC: 10uH DMC: 0.2uH

Application

MCR Series Boost Inductor • 70 x 70 x 40mm/50KW inductor • For 100KW, two phase with 50KW inductor x 2 • For 150KW, three phase with 50KW x 3 Metal Composite for • -40℃～+155℃ Hybrid • 20KHz IGBT, 50KHz SiC • Inductance: 200uH, 100uH at 200 Amp • Power Loss: 100W • Thermal Resistance: 0.18 K/W © 2019 KEMET Corporation Metal Composite Reactor

Features • Silent and lightweight with adoption of split powder dust core and minimized metal material structure • Used for both AC and DC link for boosting, smoothing and noise rejection • Largely custom design

No Solution Product series Note Boost

MCR Series MCR 1 Boost Boosting Circuit 1. Operating Temp. (Boost Inductor) -40~+180deg-C Inverter/Motor 2. Superior Design Flexibility ESD 2 Common Mode Noise - On Harness 3. Small Leakage Flux (Ferrite Core) - On Bus-Bar Common Mode Noise

200V ② ② ESD-R-SR Series ～300V 1. Operating Temp. -40~+105 deg-C 2. Effective for kHz Band (Mn-Zn) 3. High-μ Material (S15H) ① INVERTER CIRCUIT MOTOR ESD-R-M-H/N-H Series 1. Operating Temp. -40~+120 deg-C 2. Effective for kHz Band (Mn-Zn) Effective for MHz Band (Ni-Zn) 3. UL94 V-0 © 2019 KEMET Corporation 5 Snubber Capacitor

Function Connected in parallel with semiconductor components to damp voltage spikes on semiconductor switches.

IGBT Snubber

Rated Voltage: • 1200 Vdc • 1600 Vdc 2 • 3000 Vdc C = LI 2 Demanded Life Expectancy: Δ V • >10 years (100k hours)

double sided metallized polyester carrier film • Voltages: 1.2kVdc,1.6kVdc, 3kVdc polypropylene film dielectric

single sided metallized polypropylene film

metal-sprayed contact layer

Box Wire Terminals Box Tag Lug Aluminum Canister Wire terminals total capacitance Direct IGBT installation Bank configuration with parallel Internal protection

C4AS C4BS C44B

Patented C0G Dielectric Technology

Voltage and Temperature Stable

Capacitance up to 150nF

EIA 0603 – 4540 Case Sizes

DC Voltage Ratings of 500 – 3,000V

DC Voltage Rating of 10,000V Under Development

Commercial & Automotive Grades

Operating temperature range of −55°C to +125°C

Extremely high-power density and ripple current capability

Extremely low equivalent series resistance (ESR)

No capacitance shift with voltage

Surface mountable using standard MLCC reflow profiles

Low-loss orientation option for higher current handling capability

6 DC Link Capacitors

Function To support a DC network by AC/DC DC/AC supplying periodically high Converter Converter currents.

Rated Voltages: • 700 Vdc - Welders • 1100 Vdc - Wind Converters • 1300 Vdc - Wind Converters • 1500 Vdc - Solar Converters • Demanded Life Expectancy • >10 years (100k hours)

Snap-Ins Screw Terminals

• Low power drives • Medium to high power

ALC10, ALC40 ALS70/1, ALS80/1 ALS30/31, ALS40/41, PHE205 PEH526, PEH536 PEH200/169, ALS32/33, ALS42/43

Aluminum & Box Bricks Plastic Can • Best dimensional • Layout and performance • Modular configuration efficiency optimization • Lower volume efficiency • Higher power & • PCB mounting • Form factor flexibility temperature

• For DC-Link Capacitors: ‒ Lower capacitance required promotes miniaturization due to: • Increasing switching frequency • Higher voltages • Lower capacitance is within the range of MLCC. ‒ But these needs must be: • Extremely reliable • Over-temperature capable • Over-voltage capable • High current capable • Mechanically robust

3 Phase AC Generator Electrolytic ALS70 Film C44U Output V 690 Vac C μF 5,100 500 Vdc Link 1,000 Vdc Vdc 500 1,100 V Ripple Max 100 V D x L mm 77x115 85x174 Frequency 50 Hz Volume cm3 535.5 1,257.2 Capacitance 500 μF I Ripple (A) 26.5 30 Ripple 26 A Total Volume 1,071 1,257.2 Current Total C μF 2550 500 Frequency 300 Hz DC-Link Temperature 75 °C

Electrolytic (ALS70) Film (C44U)

26 A

26 A 2,550 1,100 Vdc Vdc

Total Volume Total Volume 1,071 1,257.2 2,550 μF 500 μF 4 x Required Stable over years Capacitance How long will they last?

Electrolytic Film (ALS30) (C44U)

Parametric Failure: LE = Life expectancy at operating V • Capacitance change > ±10% LN = Life expectancy at nominal voltage • ESR > 2 x initial value VN = Nominal voltage Un (V) • Impedance > 3 x initial value V = Operating Voltage (V) • Leakage current > specified limit ** Note, only valid if hot spot < 85°C • Maximum core temperature exceeded 8 LE = LN x (VN/V)

61,317 Hours (7 Years) 214,360 Hours (24 Years)

Electrolytic Film (ALS30) (C44U)

Parametric Failure: LE = Life expectancy at operating V capacitance change >±10%; L = Life expectancy at nominal voltage ESR >2 x initial value; N VN = Nominal voltage Un (V) impedance >3 x initial value; V = Operating Voltage (V) leakage current > specified limit; ** Note, only valid if hot spot < 85°C maximum core temperature exceeded 8 Electrolytic Life Calculator LE = LN x (VN/V) 23,405.861,317 HoursHours (2.67 (7 Years) Years) 214,360 Hours (24 Years) http://elc.kemet.com/ © 2019 KEMET Corporation DC Link Film Capacitor Trend

Description

Total Capacitance 360 µF 350 µF 330 µF Rated Voltage 900 Vdc 900 Vdc 900 Vdc Individual Capacitor 40µF / 900V 350uF / 900Vdc 110uF / 900Vdc Capacitors in Parallel 9 1 3 Assembly Dimensions 115 x 50 x 182 90 x 70 x 180 76 x 76 x 238 (*) Assembly Volume ( dm³ ) 1,0 1,1 1,4 Irms @ 10 KHz Tcase=70°C 180 A 90 A 100 A Theorical Stray Inductance 4 nH 10 nH 13 nH Power Dissipation High Low Medium Cost Factor 100 280 170

Max. Temperature (85 °C)

Description

Total Capacitance 360 µF 350 µF 330 µF Rated Voltage 900 Vdc 900 Vdc 900 Vdc Individual Capacitor 40µF / 900V 350uF / 900Vdc 110uF / 900Vdc Capacitors in Parallel 9 1 3 Assembly Dimensions 115 x 50 x 182 90 x 70 x 180 76 x 76 x 238 (*) Assembly Volume ( dm³ ) 1,0 1,1 1,4 Irms @ 10 KHz Tcase=70°C 180 A 90 A 100 A Theoretical Stray Inductance 4 nH 10 nH 13 nH Power Dissipation High Low Medium

Cost Factor 100 280 170

Developments: PP 100 °C Snubber and 105 C° DC-Link Box Max. Temperature (85 C) MLCC C0G Ceramic (up 200 °C) Snubber and DC-Link

ALS71 Increase capacitance and performance in same case size Rated Case Ripple Ripple ESR Impedance Capacitance Size Size Current Current Maximum Maximum Price VDC LOP Part Number 100Hz 20°C Code D x L 100Hz 10kHz 100Hz 10kHz 20°C (%) (µF) (mm) 85°C (A) 85°C (A) 20°C (mΩ) (mΩ)

450 4300 MF 66 x 105 19kh 13.28 21.45 46.35 30.35 ALS71A432MF450 93% ALS31

Rated Case Ripple Ripple ESR Impedance Capacitance Size Size Current Current Maximum Maximum Price VDC LOP Part Number 100Hz 20°C Code D x L 100Hz 10kHz 100Hz 10kHz 20°C (%) (µF) (mm) 85°C (A) 85°C (A) 20°C (mΩ) (mΩ)

450 2200 MF 66 x 105 19kh 11.1 19.3 67 47 ALS31A222MF450 100%

ALS71

Reduce case size and cost 450 2400 KF 41 x 105 18kh 8.8 15.16 79.77 51.76 ALS71A242KF450 57% by keeping CV value

Battery Voltage Boost DC-LINK H-Bridge

M1 NMOS

Q1 Q2 Q3 Reactor C2 C3 C4 L1 Aluminum Ceramic Film Motor Electrolytic L

Battery C1 Ceramic Silicon Q4 Q5 Q6 Carbide M2 NMOS

1. Calculate the impedance of each capacitor. C1 a) Use the ESR at the application frequency.

1 C2 푍퐶1 = + 퐸푆푅 2휋 ∗ 퐹푟푒푞 ∗ 퐶퐶1 Input Current

C…

1. Calculate the impedance of each capacitor. PEG1 a) Use the ESR at the application frequency.

1 PEG2 푍 = + 1.5Ω = 35.36Ω 푃퐸퐺1 2휋 ∗ 100퐻푧 ∗ 47푢퐹 1Arms

1 C4AE1 푍 = + 1.5Ω = 35.36Ω 푃퐸퐺2 2휋 ∗ 100퐻푧 ∗ 47푢퐹

C4AE2 1 푍 = + 8.1푚Ω = 159.16Ω 퐶4퐴퐸1 2휋 ∗ 100퐻푧 ∗ 10푢퐹

1 푍 = + 8.1푚Ω = 159.16Ω 퐶4퐴퐸2 2휋 ∗ 100퐻푧 ∗ 10푢퐹

1. Calculate the impedance of each capacitor. C1 a) Use the ESR at the application frequency. 2. Calculate the total impedance in the bank. C2 −1 1 1 1 1 푍푇표푡푎푙 = + + ⋯ + + Input Current 푍퐶1 푍퐶2 푍퐶… 푍퐶푁 C…

1. Calculate the impedance of each capacitor. PEG1 a) Use the ESR at the application frequency. 2. Calculate the total impedance in the bank. PEG2 −1 1 1 1 1 푍 = + + ⋯ + + = 14.47Ω 1Arms 푇표푡푎푙 35.36Ω 35.36Ω 159.16Ω 159.16Ω C4AE1

C4AE2

1. Calculate the impedance of each capacitor. C1 a) Use the ESR at the application frequency. 2. Calculate the total impedance in the bank. 3. Calculate the current through each capacitor. C2 a) Compare the calculated current with the rated current for that part at the application frequency. Input Current b) If the calculated current is higher than the rated current, look C… into another solution or discuss lifetime of the part with a PM.

푍푇표푡푎푙 퐼퐶1 = 퐼푇표푡푎푙 CN 푍퐶1

1. Calculate the impedance of each capacitor. PEG1 a) Use the ESR at the application frequency. 2. Calculate the total impedance in the bank. 3. Calculate the current through each capacitor. PEG2 a) Compare the calculated current with the rated current for that part at the application frequency. 1Arms b) If the calculated current is higher than the rated current, look C4AE1 into another solution or discuss lifetime of the part with a PM.

14.47Ω C4AE2 퐼 = 1퐴푟푚푠 = 0.4091퐴 푃퐸퐺1 35.36Ω 퐼푅퐴푇퐸퐷 = 0.328퐴 14.47Ω 퐼 = 1퐴푟푚푠 = 0.4091퐴 퐼 = 0.328퐴 푃퐸퐺2 35.36Ω 푅퐴푇퐸퐷 14.47Ω 퐼 = 1퐴푟푚푠 = 0.0909퐴 퐼 = 6.5퐴 퐶4퐴퐸1 159.16Ω 푅퐴푇퐸퐷 14.47Ω 퐼 = 1퐴푟푚푠 = 0.0909퐴 퐶4퐴퐸2 159.16Ω 퐼푅퐴푇퐸퐷 = 6.5퐴 © 2019 KEMET Corporation Capacitor Impedance Example: 1Arms at 100kHz Recommended Solution

1. Calculate the impedance of each capacitor. ALC40 a) Use the ESR at the application frequency.

1 C4AE1 1Arms 푍퐶1 = + 퐸푆푅 2휋 ∗ 퐹푟푒푞 ∗ 퐶퐶1

1 C4AE2 푍 = + 990푚Ω = 16.91Ω 퐴퐿퐶40 2휋 ∗ 100퐻푧 ∗ 100푢퐹

1 푍 = + 8.1푚Ω = 159.16Ω 퐶4퐴퐸1 2휋 ∗ 100퐻푧 ∗ 10푢퐹

1 푍 = + 8.1푚Ω = 159.16Ω 퐶4퐴퐸2 2휋 ∗ 100퐻푧 ∗ 10푢퐹

1. Calculate the impedance of each capacitor. 푍퐴퐿퐶40 = 16.91Ω ALC40 a) Use the ESR at the application frequency. 푍퐶4퐴퐸1 = 159.16Ω

푍퐶4퐴퐸2 = 159.16Ω 2. Calculate the total impedance in the bank. C4AE1 1Arms 1 1 1 1 −1 푍푇표푡푎푙 = + + ⋯ + + 푍퐶1 푍퐶2 푍퐶… 푍퐶푁 C4AE2

1 1 1 −1 푍 = + + = 13.94Ω 푇표푡푎푙 16.91Ω 159.16Ω 159.16Ω

푍 = 16.91Ω 1. Calculate the impedance of each capacitor. 퐴퐿퐶40 ALC40 a) Use the ESR at the application frequency. 푍퐶4퐴퐸1 = 159.16Ω

푍퐶4퐴퐸2 = 159.16Ω 2. Calculate the total impedance in the bank. C4AE1 푍푇표푡푎푙 = 13.94Ω 1Arms 3. Calculate the current through each capacitor. a) Compare the calculated current with the rated current for that C4AE2 part at the application frequency. b) If the calculated current is higher than the rated current, look into another solution or discuss lifetime of the part with a PM. 푍푇표푡푎푙 퐼퐶1 = 퐼푇표푡푎푙 푍퐶1 13.94Ω 퐼 = 1퐴푟푚푠 = 0.8248퐴 퐼 = 0.85퐴 퐴퐿퐶40 16.91Ω 푅퐴푇퐸퐷 13.94Ω 퐼 = 1퐴푟푚푠 = 0.0876퐴 퐼 = 6.5퐴 퐶4퐴퐸1 159.16Ω 푅퐴푇퐸퐷 13.94Ω 퐼 = 1퐴푟푚푠 = 0.0876퐴 퐶4퐴퐸2 퐼푅퐴푇퐸퐷 = 6.5퐴 159.16Ω © 2019 KEMET Corporation Thank You!