SMART SYSTEM – POWER ELECTRONICS

THE CHALLENGE: INTELLIGENT GATE DRIVERS

Power electronics have a substantial influence on the development of electric vehicles. Because the efficiency of the “drive” system as a whole is largely dictated by the electronics and control systems. The electronics are traditionally split into power electronics and controllers.

Especially in the case of high-frequency 48 V motors where, for design reasons, the inductance of the motor is very low, it is crucial to locate the power electronics as close to the motor as possible - i. e. at the windings.


THE COOPERATIVE SOLUTION: CONNACTIVE

Here, too, CONNACTIVE is leveraging its tried and tested expert network to develop viable technical solutions. Alvier Mechatronics with their long-standing development experience, global player Vishay with its broad component portfolio, circuit carrier developers and distributors working with their field application engineers – all combined to create the perfect ecosystem. Expertise is systematically consolidated, with all partners cooperating in the targeted development and delivery of new solutions.

THE KEY FACTORS!

The direct integration of power electronics in the motor poses new challenges, especially in the areas of electronics packaging and heat dissipation. How does the cooling system need to be designed to make sure that both the electronics and the stator are optimally cooled? How can the windings be connected to the electronics to robustly meet all durability requirements and with due regard for the high thermal input from the windings to the circuit carrier, which is bound to occur?

System integration places high demands on design, processes and materials.

Through our choice of components, we achieve balance in the circuit, i. e. low on-state losses with simultaneously low switching losses.

SYSTEM INTEGRATION OF POWER AND CONTROL COMPONENTS

Requirements:

  • reduction of system prices
  • reduction of installation space
  • temperature and heat management capability
  • product stability and reliability

HIGH CURRENT ON PRINTED CIRCUIT BOARDS

The requirements for the configuration of the circuit boards are as follows:

  • low power losses in the high-current tracks (energy efficiency and minimal temperature rise)
  • high conductor cross-sections for the currents to be switched, as well as fine structures, for a combination of power and control electronics on a single board.

Solution: adapted integrated copper inlays in standard PCB technology

  • component heat dissipation through the circuit board using copper inlays
  • logic and power on the same plane

Space requirement (calculation example): 

thickness: 400 μm 

Δ T 45 K 

current: 100 A 

width: 16 mm 

width 70 μm Cu:  37 mm 

space savings: 57 % 

ADVANTAGES of the integrated COPPER PCB

The high-current printed circuit board has proven to be a high-performance solution for our drive systems:

Solid copper is embedded in the circuit board and can be directly populated on SMD pads that extend to the surface. The main advantage is the use of surface-mount technology on these circuit boards: The configuration permits direct solder contact of components with the internal copper cross sections of 10 mm² and more.

This convincing PCB technology offers a high degree of freedom in the design of the solid copper layers, which means that a technically feasible solution can be found for almost every application.

 

  • Winding directly onto copper (special copper version)
  • Direct pathway, direct connection to heat sink
  • Heat is transferred to the heat sink located directly behind it
Mustafa Dinc Portrait

VP Business Development Automotive, Vishay

Mustafa Dinc

“In terms of highly efficient solution development, CONNACTIVE has achieved a further co-creation milestone: the clever integration of power electronics in new drive systems. High performance solutions made possible through motor and electronics development from a single source".

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