Electric and Hybrid Vehicle Components and Systems

Electric and Hybrid Vehicle Components and Systems

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Description: This energy presentation is about Products for Electric and Hybrid Vehicles that contains Electric and Hybrid Vehicles that reduce CO2 emissions are equipped with some specific products not found in conventional gasoline powered vehicles. DENSO provides products based on its cutting‑edge technologies. These include traction inverters for controlling electric drive motors and regenerating energy, and drive battery monitoring units for power electronics systems.

Traction inverters are critical to the control of electric motors. DENSO provides inverters boasting the world stop discharge power density with a new cooling technology that limits temperature levels in built‑in semiconductor power devices*. This cooling technology is based on both radiator cooling technologies and electronics technologies that have been developed through in‑house production of semiconductor devices.

DENSO will continue to assist the advancement of hybrid vehicles by developing new technologies and products. Power Control Unit - Higher output power is required for luxury hybrid vehicles, as well as smaller packaging for full‑line implementation of hybrid systems. DENSO has achieved 60% increase in power density (output power per unit volume) from conventional models by a dramatic improvement of cooling performance.

High voltage relay for the safety and protection of hybrid systems. By arranging magnets opposite each other and lengthening the arc path with magnetic force, it all ...Please navigate Paper pages for more details.

 
Author: Denso (Fellow) | Visits: 3173 | Page Views: 3851
Domain:  Green Tech Category: Transportation Subcategory: PEVs 
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Contents:
Products for Electric and Hybrid Vehicles
Electric and Hybrid Vehicles that reduce CO2
emissions are equipped with some specific products
not found in conventional gasoline powered vehicles.
DENSO provides products based on its cutting-edge
technologies. These include traction inverters for
controlling electric drive motors and regenerating
energy, and drive battery monitoring units for power
electronics systems.

Traction inverters are critical to the control of electric
motors. DENSO provides inverters boasting the
world’ top discharge power density with a new
s
cooling technology that limits temperature levels in
built-in semiconductor power devices*. This cooling
technology is based on both radiator cooling
technologies and electronics technologies that have
been developed through in-house production of
semiconductor devices.
DENSO will continue to assist the advancement of
hybrid vehicles by developing new technologies and
products.
*Power devices are electronic components that act as switches to turn on and off the flow of high current.

Products for Electric and Hybrid Vehicles
Press the button to see your selected product.

DC-DC Converter

Hybrid Vehicle
Electronic Control Unit

System Main Relay

Battery Current Sensor

Motor Stator for
Small Hybrid Vehicle

Electric Compressor

Battery Monitoring Unit for
Lithium-ion Batteries

Power Control Unit

Power Control Unit
■Outline
 ●Higher output power is required for luxury hybrid vehicles, as well as smaller packaging for full-line    
  implementation of hybrid systems.
 ●DENSO has achieved 60% increase in power density (output power per unit volume) from conventional
  models by a dramatic improvement of cooling performance.
■Feature
View

Power Chips
B

Double-Sided Power Module
Cooling Tubes

A

【New Design】 Double-Sided
Cooler

Section A-A
Outlet

Stacked
Double-Sided Cooler

A

B
Coolant
Power Chips

Coolant
Inlet

Diaphragm
Construction

【Conventional Design】 Single-Sided
Cooler

Section B-B

Power Control Unit
■Engineering Key Point

■Benefit

 ●Double-sided power module for improved cooling

 ●Diaphragm construction for improved adhesion of
  power module and cooler

DENSO Inverters
(double sided cooling)
Ratio of Power Density

 ●Stacked double-sided cooler for improved cooling

2.5

2.0

1.5

Conventional Inverters
(single sided cooling)

1.0

0.5

0

Output power

Power density :
Output power per unit volume

System Main Relay (SMR)
High voltage relay for the safety
and protection of hybrid systems.

Contact

Opposed magnet arrangement

Magnets for
arc extinction

Unsealed
contact
chamber

40

Specifications
Contact rating

DC360V 60A

On-off cycle life

More than 100,000 times

Dimensions

40mm × 37mm × 50mm

Weight

0.17kg

50

 ●By arranging magnets opposite each other
  and lengthening the arc path with magnetic force,
  it allows the arc to be extinguished in a smaller space
 ●Reduced size by using an unsealed contact chamber

37

Arc path
(Effect of magnets)

Relays in the system

R ly
ea

Man

b tey
at r
R ly
ea

Inverter

Electric Compressor
■Outline

Co-development product with TOYOTA INDUSTRIES CORPORATION

 ●A conventional compressor is hardly possible to be applied to EV and HV because it is driven by engine.

 ●It is not necessary to drive engine for air conditioning. → Fuel efficiency improved.
Vehicle

■Feature
 ●The world first Mass-production electric compressor
integrated inverter and motor.

 ●Compact size almost same as a conventional compressor.
 ●Minimizing mass increase for vehicle fuel/power efficiency.

Luxury

34cc/rev.

Large
27cc/rev.
Medium

Compact

 ●Low noise/vibration design for quiet environment.
 ●3 varieties covering from small-class vehicle to luxury-class.

Electric Compressor

14cc/rev.
Small
cc/rev : Voluminal displacement per revolution

Electric Compressor
■Engineering Key Point

Small displacement / High speed /
Small internal loss scroll

Compact Inverter
Inverter / Motor cooled by suction
refrigerant gas (low temperature)

Refrigerant flow

High Efficiency / Low Vibration Motor

■Benefit
Electric compressor improves fuel consumption by maximum 19%, compared to
conventional compressor (Belt-driven compressor) for HV.

DC-DC Converter
DC-DC converter designed to recharge the auxiliary battery
Can be integrated into a power control unit
 ●Reduced conversion loss by using
  DENSO's original dual transformer system
  (fewer circuit elements, synchronous rectification)
 ●Simplified structure and reduced transformer
  winding loss by integrating magnetic parts
 ●Improved heat dissipation efficiency
  by optimally arranging circuit elements

14V
288V

Synchronous
rectification

Specifications
Nominal input voltage

288V

Output voltage

13V to 15V Controllable

Max. output current

120A

Max. efficiency

96%

Dimensions

360mm × 95mm × 105mm

Weight

2.7kg

Transformer

Complex dual
transformer

Choke coil


Integration
(Volume : −12%)

Battery Current Sensor
Current sensor to detect the current flow and monitor the state of the main battery charge.
● Simple structure consisting only of a Hall IC
and a core

■ Structure

● No printed board or soldering required
● Input and output terminals with capacitors for
improved noise reduction

Specifications
Supply voltage range

3%FS

Dimensions

47mm × 37mm × 17mm

Weight

34g

Capacitor

Terminal

Case with
embedded
connector

−200 ∼ +200A

Accuracy after reliability test

Hall IC

DC5.0 ± 0.5V

Measured current range

Core

Current
Core
Magnetic flux
Hall IC
Voltage

Measured
current

Noise

Terminal

Capacitor

Battery Monitoring Unit for Lithium-ion Batteries
■Outline
 ● It is expected for Battery Monitoring Unit to control the battery’ voltage highly accurately in order to  
s
  operate lithium-ion batteries safely and efficiently.
 ●Compared to the conventional voltage control method, DENSO’ new method enables to control the
s
  voltage of each cell and eliminate the fluctuation among the cells at lower cost.

Battery Monitoring Unit for Lithium-ion Batteries

Comparison Judgment
Circuit
Circuit

Discharge
Circuit

Measure the voltage of
each cell and detect the
cells which have
higher-voltage than the
target level using a
microcomputer and
enable all cells to
discharge at the same
level.

Voltage Detection Circuit

Microcomputer

Logic Circuit

Compare the cell
voltage with the
average for cell’
s
discharge by using a
simple circuit.

Target

A/D

Average

I/F

■Feature

Discharge Circuit

Newly developed voltage control method

Conventional voltage control method

Simple circuit structure without an
A/D circuit or a microcomputer

I/F: Interface circuit
A/D:Analog to digital conversion circuit

■Engineering Key Point
The function of new voltage control method is to compare the single cell voltage with the average
voltage of all cells for cell’ discharge by using a simple circuit.
s

Hybrid Vehicle Electronic Control Unit(HV-ECU)
ECU to control overall hybrid system in a hybrid vehicle
●Control traction of motor and engine, HV battery,  
 regenerative braking and other functions.

Brake ECU

HV-E
CU

Specifications

CPU

32-bit Processor
Multi-core Lock step
200MHz

Dimensions

160mm × 150mm × 35mm

Electronic
throttle

Weight

0.3kg

Battery monitoring unit
DC/DC
Converter

Injector

Clock speed

Hybrid
system
control

Engine
control

IC Engine
sensors

12V

Shift position sensor
(Air conditioning ECU, etc)

CAN Bus

Nominal input voltage

Accelerator
pedal sensor

12V

Igniter
Main
battery
(245V)

MG-ECU
Power
splitter

Inverter

MG1

MG2

Boost converter

High voltage
relays

Motor Stator for Small Hybrid Vehicle
■Outline
 ●Low fuel consumption and low emission small size HV is expected so that a high voltage down sized
  motor is required to be carried by small size HV.
 ●A downsized stator for small HV can be developed by utilizing a newly developed coil, winding structure
  and production method. The stator contributes to development of small size HV.
■Feature
Reduction in size of end winding by utilizing
newly winding structure and insulation

End winding

Coil

Coil
Space factor
+10%

Coil

Stair shaped coil
Lc

Lc"

Core

【Conventional】

Increase of space factor of coil by utilizing rectangular coils
Cross sections
of core

End windings of motor stator
Insulation
paper

Core

Lc > Lc"

【Developed】

Separated
core

【Conventional】

【Developed】

Separated cores inserted into
a group of completed winding
Outer ring
Winding
Separated core

Motor Stator for Small Hybrid Vehicle
■Engineering Key Point
Newly developed coil

Coil with stair like shape

Stator coil
Enamel layer

Conductor

【Conventional】

Shape of end winding
Enamel layer
Resin layer

Conductor

【Developed】

■Benefit
Downsizing of stator

Reduction in size of end winding

▲10%

Core

Core

【Conventional】

Conventional stator

Stair shaped Coil

【Developed】

Cross section of T/A

▲15%
Front side

Width -10%
Height -15%

Developed Stator

Rear side

Motor

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