VPPC Terry Hosking, V.P. of Engineering SBE Inc.

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1 VPPC 2009 Comparative Evaluation and Analysis of the 2008 Toyota Lexus, Camry and 2004 Prius DC Link Capacitor Assembly vs. the SBE Power Ring DC Link Capacitor --- Terry Hosking, V.P. of Engineering SBE Inc. 1

2 Introduction Purpose of evaluation: 1. Determine Trise of DC link capacitor designs used in Toyota hybrid vehicles 2. Compare Toyota capacitor Trise with available SBE and Kemet DC link capacitor Trise 3. Consider impact to new PEM designs 2

3 Test Logistics 1. Toyota and Kemet DC Link capacitors were supplied by Oak Ridge National Labs (ORNL), National Transportation Research Center (NTRC) facility in Knoxville, TN 2. Thermocouple placement done at SBE 3. Tests conducted by NTRC staff in Knoxville 3

4 DC Link Capacitors Tested Toyota Camry Toyota Lexus Toyota Prius [1 new & 1 used for 160Kmiles] KEMET 2600uF [no part number, appeared to be designed for Lexus] SBE 500uF 700D349 SBE 1000uF 700D348 4

5 Toyota Camry 5

6 Toyota Lexus 6

7 Toyota Prius 7

8 KEMET 2600uF 750V 8

9 SBE 500uF 600V 700D349 9

10 SBE 1000uF 600V 700D348 10

11 Capacitor Description Summary Source Voltage Rating DC Link Capacitance Approximate Dimensions Volume (cm 3 ) Surface Area (cm 2 ) 1 Camry mm L 178mm W 73mm H Lexus mm L 171mm W 51mm H Prius mm L 184mm W 41mm H Kemet mm L 171mm W 51mm H SBE mm D 48mm H SBE mm D 48mm H

12 Thermocouple Placement 1. Challenge is to determine meaningful locations for thermocouples 2. Goals a) anticipate a hot-spot location b) investigate terminal heating effects c) determine case temperature d) look at internal T at other locations 12

13 Thermocouple Placement 1. TC placement via holes drilled into capacitor windings in addition to case surface locations 2. For AC Trise measurements, this is OK for metallized capacitors 3. Capacitors may no longer support much DC, so the test sacrifices capacitor functionality 4. Since the internal construction was unknown, where to drill holes??? 13

14 Thermocouple Placement 1. X-Ray examination needed Local medical X-Rays obtained For capacitors with single windings some detail observed For complex assemblies they were of no help 2. CT scans obtained from North Star Imaging These were supplied with software for 3D imaging and allowed 2D sections to be obtained and saved as.jpg files Provided ALMOST enough detail. 14

15 Typical CT Scan Top View 15

16 Typical CT Scan Side View 16

17 Lexus Capacitor Thermocouple Placement CT scans did not show fine interconnect detail, especially thin copper sheet. a. This created problems, as after drilling the Lexus capacitor it was shorted! b. Parallel plate interconnect [to reduce ESL] was not shown on the CT image; c. Capacitor repaired by careful use of larger sharp carbide drill to expose and remove layer to layer short circuits. 17

18 Lexus Capacitor Thermocouple Placement x11 x10 x12 x8 x9 x12 x9 x10 x11 x13 18

19 Lexus Capacitor Thermocouple Placement 19

20 Thermocouple placement [Camry] 20

21 Thermocouple Placement [Prius] 21

22 Simulated Temperature Profile (SBE) 5000 second simulation temperature profile indicating predicted hot spot 22

23 SBE 1000uF 600V Thermocouple Placement SBE 700D348 Prior to Encapsulation 23

24 SBE 500uF 600V With Thermocouples SBE 700D349 as Tested on a Bus Assembly 24

25 Test Description All capacitors tested at 200ARMS, 5KHz Test frequency [5KHz] defined by capability of NTRC test stand to source 200ARMS into all capacitors Chamber temperature set to 25C 25

26 Test Description Example of a capacitor under test inside thermal chamber 26

27 Test Description Sine wave signal generator ITECO Powertron 1000A PA 2 1 LEM LC300S CT ESPEC Temperature Chamber Capacitor under test PA PA 5 total I V Yokagawa PZ4000 Power System Analyzer Keithley 2701 Thermocouple Data Acquisition NTRC capacitor current source and data acquisition schematic 27

28 Test Description Amplifier stack at ORNL-NTRC 28

29 Test Observations Higher test frequency would have been desirable to represent typical switching frequencies The low test frequency masks the following effects: current hogging [not all windings in cap assy. see the same current] skin effect conduction losses eddy current losses Substantial capacitor heating from connection and terminal conduction losses was seen in Toyota and Kemet Capacitors 29

30 Temperature ( C) Lexus Data, Thermocouples #8 - #13 Lexus Cap. (5kHz, 200A, 25 C ambient) Delta T Time (sec.) Delta T ( 9-13 ) 30

31 Lexus Thermocouple Placement x11 x10 x12 x8 x9 x12 x9 x10 x11 x13 31

32 Highest Temperature Measurements 32

33 Measured internal Trise of tested capacitors 33

34 SBE Capacitor Test Result Comments 1. The highest Trise location was not where simulation predicted! a) back to the drawing board needed are: Better simulation boundary conditions Better values for materials parameters b) SBIR funded research has provided those for ongoing and future simulations 2. Distributed connection significantly lowers Trise! 34

35 Simulated Temperature Profile (SBE) 35

36 Summary of Test Results Trise of the SBE capacitors was substantially lower than any of the Toyota or Kemet designs Prius capacitor had the highest Trise Capacitor from the 160,000 mile Prius exhibited no performance degradation 36

37 Summary of Test Results Lexus capacitor substantially smaller size, yet only a small Trise increase as compared to the capacitor used in the Camry Kemet capacitor performance was similar to that used in the Lexus, but with higher capacitance and ~2.5 C lower Trise 37

38 Capacitor Analysis Design: Film: Dielectric stress: (at rated V) Prius 3.8u 150V/u Camry 3.5u 214V/u Lexus 3u 250V/u Kemet 3u 250V/u SBE 3.8u 150V/u

39 Capacitor Performance Drivers Assuming constant capacitance: +Reliability? Reduce T, V/u [size increase] Higher T? Reduce V/u [size increase] Higher I? Change winding shape from paper towel roll toward hockey puck

40 Capacitor Cost Drivers Capacitance value! [determines film usage] Film cost vs thickness, especially below 3.8u [where cost increases faster than the capacitance gained!] Capacitor assembly complexity

41 Implications The SBE capacitor design could allow power conversion systems with lower cost, volume, and weight without sacrificing current carrying capability. The lower Trise could result in: Less capacitance required, and/or Higher system reliability, and/or Higher system operating temperature, and/or Easier thermal management. 41

42 Future Work Characterization of Power Ring Trise at higher current and frequency [SBE Test hardware construction and verification is complete; over 500ARMS ~19KHz] Continue with tests comparing other capacitor vendors including AVX, CDE, EPCOS, ECI, and others as we become aware of them. Use of bus structure as a capacitor cooling medium in addition to its reduction of connection losses. High stress Trise data to be gathered as illustrated in following graph. 42

43 Future Work 43

44 VPPC 2009 Thank you! Please visit our booth. 44

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