Electric vehicle dc converter dismantling

TDK has begun offering "DC-DC converters" to hybrid and electric vehicles. Electric vehicles charge batteries with voltages up to hundreds of volts. The DC-DC converter reduces the voltage of the rechargeable battery to 14V and supplies it to the lead storage battery. The lead storage battery is used as a power source to drive the engine's auxiliary machine, wiper and headlights.

The world's first mass-produced hybrid car has been in use for 12 years. Including TDK, the power density per unit volume of DC-DC converters has increased year by year, and it is estimated that this trend is also in the future.

TDK's DC-DC converter was actually used in hybrid vehicles in 1997. Honda will be used on the current Civic Hybrid and the new Insight (Figure 1). It has also been applied to hybrid vehicles by some overseas manufacturers.

The reason why Insight uses the DC-DC converter manufactured by TDK is because it can meet the requirements of small size and light weight. Honda reduced the size of PCU (power control unit) including DC-DC converters and inverters and the size of Ni-MH rechargeable batteries to Insight. These devices were placed behind the rear seat in the Civic Hybrid and in the Insight under the luggage compartment to increase the available space in the luggage compartment. The miniaturization of the DC-DC converter helps to expand the luggage compartment capacity and reduce costs.

The latest DC-DC converters used in Insight are 45% lighter and 5% smaller than the original products on the Civic Hybrid (Figure 2). The weight is less than 1kg. Conversion efficiency is guaranteed to be above 90%.

By eliminating the need for an alternator hybrid vehicle and an electric vehicle to be introduced into a DC-DC converter, the alternator can be omitted. The alternator uses the rotary power of the engine to generate electricity to charge the lead battery. (pictured)

The rechargeable battery of an electric car has a large capacity. Therefore, with the rechargeable battery as the power source, the lead-acid battery can be charged by the DC-DC converter. This eliminates the need for the original alternator. (pictured)

Insight is not equipped with an alternator (pictured)

With a rechargeable battery and a DC-DC converter, the lead battery can be charged without regard to the engine speed. In the original gasoline engine car, when the engine speed is low, if the air conditioner, stereo, and lights are used at the same time, sometimes the battery will be exhausted. Even if the engine is still running, there will be power shortages under some conditions. And if a rechargeable battery and a DC-DC converter are used like a hybrid car and an electric car, power can be used regardless of the engine speed.

Hybrid vehicles and electric vehicles can also save lead batteries, but actually retain lead batteries (pictured). Insight also retains lead batteries. There are two main reasons for doing this. First, the preservation of lead storage batteries can reduce the cost of the entire vehicle. The second is to ensure the redundancy of the power supply.

Lead storage batteries can discharge large currents to air conditioners, wipers, and lights in a short period of time. If the lead-acid battery is omitted and the power of the rechargeable battery is used for the replenishing type, the air conditioner, and the wiper, the size of the DC-DC converter is bound to increase, thereby increasing the overall cost. Lead batteries are cheap, so there is no cost advantage in replacing lead batteries with rechargeable batteries.

Second, the lead storage battery also has the effect of ensuring the redundancy of the power supply to the replenishing machine. When the DC-DC converter fails and the power supply is stopped, if there is no lead battery, the replacement class will stop running immediately. When the nighttime lights are not lit, the rainy day wipers stop running, etc., it will affect the driving. If you have a lead battery, you can drive your car to your home or factory.

One of the future directions for the improvement of DC-DC converter function is bidirectional. The DC-DC converter used now only changes the voltage in one direction. There is also a need for two-way requirements. When the power of the rechargeable battery is insufficient, the power of the lead storage battery can be input into the rechargeable battery for emergency needs. Two-way is a topic that will continue to be explored in the future, and this is also a way to ensure redundancy. TDK has developed the basic circuit (platform) of DC-DC converter, as shown in the figure.

These include "GEN3" (3rd generation), which was mass-produced in 2001, "GEN4" (4th generation), which was mass-produced in 2005, and "GEN4.5" (4.5th generation), which was mass-produced in 2008. What is being developed is "GEN5" (5th generation). According to the basic circuit, a product that meets the requirements of each automobile company is produced.

Different generations of DC-DC converters specify the type of transformer and the basic structure of the DC-DC converter circuit. Water cooling/air cooling, terminal position, body shape, etc. are designed according to the adopted model. The basic structure is designed on the premise of air cooling in a harsh environment.

According to the product, the conversion efficiency has been increasing from the 2nd generation to the 5th generation (Fig. 8). When the current is 10 A, the conversion efficiency is about 84% (2nd generation), about 86% (4th generation), and about 89% (4.5th generation). At a current of 70 A, the conversion efficiency is increased from about 86% (2nd generation) to about 88% (4.5th generation). It is expected that the next generation of the fifth generation will exceed 90%. (To be continued, special contributor: Kondo Hiroshi, Minister of EV Power Division, TDK Power Systems Business Group)

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