New concepts of capacitor designs in power electronics. Dr. Thomas Ebel

Transcription

1 New concepts of capacitor designs in power electronics

2 FTCAP GmbH - Company Profile Fischer & Tausche was founded 1948 in Husum 100 % family owned Production and distribution of electrolytic- and metalized film capacitors Focus on individual developments and customized design Acquisition of Leclanché Capacitors (Switzerland) in Mio euro group sales 180 people in Husum + 20 people in Yverdon Exclusively manufacturing in Germany and Switzerland

3 FTCAP GmbH - Company Profile - Locations Headquarters FTCAP GmbH Carl-Benz-Str. 1 D Husum Products: metalized film and Aluminium electrolytic capacitors Subsidiary Leclanché Capacitors Sàrl 48, avenue de Grandson CH-1400 Yverdon Products: foil and metalized film capacitors

4 Product Range - Aluminium Electrolytic Capacitors Screw Terminals Snap-In Solder Lug Motor Start Special Type Axial Cuboid Axial Cuboid Radial Discharge Capacitors

5 Product Range - Metalized Film Capacitors Coax Cap Energy Cap High Voltage Power Box Special Types Joule Cap Castor Cap Power Link

6 Product Range - Customized Capacitor Solutions

7 New concepts of capacitor designs

8 FischerLink Capacitor - Concept Problem Clear trend towards higher switching frequencies is taking into account the new GaN or SiC high power semiconductor materials Low inductive constructions become more and more important Solution approach FTCAP has invented and patented a new concept of film capacitor A Fischer Link capacitor is an assembly of film capacitors were the winding is directly mounted (soldered) to the busbar Advantages: Saving space ( leading to a higher power density) Saving costs Inductance compared to standard screwed capacitor busbar assemblies is significantly lower Only one part has to be ordered Capacitor is isolated and therefore potential free and has significant longer life time

9 Fischer-Link Capacitors - Experimental data Comparative tests of FischerLink capacitors vs. standard capacitor were performed using a so-called double pulse test The Double pulse test is an established method to measure parasitic inductances in Power electronics That pulse creates an overshoot voltage according to U = L di/dt which could easily be measured Differences of the over voltages are a measure for the inductance L of the system Direct measurements of the inductance L were performed using a HP3577A network analyzer Film Capacitors: (I) Standard; (II) Low inductive (Screw); (III) Low inductive soldered ( Fischer Link )

10 FischerLink Capacitors - Experimental data A FischerLink capacitor is attached to an IGBT switch with its driver, triggered with a pulse generator over its load represented by an inductance The overvoltage is monitored with an oscilloscope The overall current is measured by a Rogowski coil

11 FischerLink Capacitors - Experimental data Tag Description 1 Oszilloskope (Tektronix // TDS 3014B) 2 Pulse generator (Ing.Büro M.Billmann // P02_PMG 02A) 3 Rogowski current waveform transducer (PEM // CWT 1B) 4 Digital DC power supply (PCE Power Control // A6KW ) 5 DC multi-output power supply (Peaktech // 6035 D) 6 Load coil (in-house manufacturing) 7 Device under test 8 IGBT module with driver 9 Connection device (in-house manufacturing) A capacitor (7) (here Fischer Link ) is attached to an IGBT switch with its driver (8), triggered with a pulse generator (2) over its load represented by an inductance (6) The overvoltage is monitored with an oscilloscope (1) The overall current is measured by a Rogowski coil (3)

12 FischerLink Capacitors - Results and discussion No Connection C/µF DF/% ESR/m Ω Pulse/V I screw std 877 1,21 2,2 1,98 43 II screw 886 1,37 2,47 1,88 33 III soldered 894 0,93 1,65 1,04 21 L/n H Inductance of the Fischer Link capacitor is the half of the standard capacitor (21 nh vs. 43 nh) and the respective pulse voltage reduction is also nearly the half. Reduction from 1,98 V to 1,04 V No Connection Height in mm L/nH I screw std 96,3 43 II screw 95,2 33 III soldered 83,7 21 It is obvious that beside the advantage of the low inductance the total height is significantly lower for the Fischer Link capacitor system

13 FischerLink Capacitors - Applications FischerLink Low inductive IGBT connection

14 FischerLink Capacitors - Applications FischerLink integrated bus bar cooling

15 FischerLink Capacitors - Applications 3 Phase Power Stack Danfoss VAC Back-to-Back-(AC/AC) 200A/300A Parallel - Configuration (DC/AC) 400A/600A (6 x 300/450A V Module) Switching f 2-12 khz DC-Link-Capacitance 4 mf

16 FischerLink Capacitors - Applications 16 kw/l kva 3 - phase SiC Power Stack Reference Design CONTROLLED BY FEATURES 16 kw/l power density Up to 130 C Tj Peak efficiency 98% Up to 20 khz switching Frequency 700 V DC / 200 A RMS COMPONENTS Wolfspeed SiC MOSFETs CAS300M12BM2 AgileSwitch 62EM1 Gate Driver FTCAP Custom Capacitor Bank MERSEN Compact water cooled MERSEN Custom Laminated Bus Bar MERSEN Custom Laminated Bus Bars AgileSwitch High Efficiency Drivers FTCAP Custom Capacitor Design BENEFITS Power modules, Bus bar, Cooling, Gate drivers and Capacitors can now be optimally designed together in one step to answer electrical, mechanical and thermal challenges of the system. APPLICATIONS EV or HEV heavy-duty vehicle E-Mobility MERSEN Custom Compact Cold Plate

17 FischerLink Capacitors - Applications Special insolation of terminals of Fischer Link capacitors for HV New insolation material 20 kv/mm Small parallel windings Bigger surface 200µF/3 kv ca. 200 A ripple current capability

18 Thank you very much for your attention! Questions / Comments / Suggestions?