Electronics Revolutionizing EVs: Key Component Manufacturing
As the automotive industry pivots towards sustainability, electric vehicles (EVs) have emerged as pivotal players in reducing carbon emissions and fossil fuel dependency. Central to their success are the intricate components manufactured within the electronics industry. These components, ranging from batteries to control systems, are not only revolutionizing transportation but also reshaping electronic manufacturing landscapes.
In this exploration, we delve into the manufacturing processes, technologies, and considerations vital to producing these key EV components. By examining the intersection of the electronics and automotive sectors, we uncover the innovations, challenges, and opportunities propelling the electric mobility revolution. Through this lens, we gain insights into how the electronics industry is driving the transformation of transportation towards a cleaner, more sustainable future.
INFINEON INTRODUCES PSOC™ 4 HVPA-144K MICROCONTROLLER FOR AUTOMOTIVE BATTERY MANAGEMENT SYSTEMS
With the introduction of the PSoC 4 High Voltage Precision Analog (HVPA)-144K microcontroller, Infineon Technologies AG addresses the automotive battery management sector by integrating high-precision analog and high-voltage subsystems on a single chip.
It provides a fully integrated embedded system for monitoring and managing automotive 12 V lead-acid batteries, which is critical for the 12 V power supply of vehicles' electrical systems. The new microcontroller is ISO26262 compliant, enabling compact and safe intelligent battery sensing and battery management in modern vehicles.
The PSoC 4 HVPA-144K’s dual high-resolution sigma-delta ADCs, together with four digital filtering channels, enable accurate measurement of the battery’s state-of-charge (SoC) and state-of-health (SoH) by measuring key parameters such as voltage, current, and temperature with an accuracy of up to ±0.1 percent. The device features two programmable gain amplifiers (PGAs) with automatic gain control, allowing fully autonomous control of the analog front end without software intervention. The use of shunt-based current sensing for batteries provides a higher accuracy than conventional Hall sensors.
An integrated 12 V LDO (42 V tolerant) allows the device to be supplied directly from the 12 V lead-acid battery without the need for an external power supply. An integrated transceiver allows direct communication with the LIN bus. The product meets the functional safety requirements of ASIL-C according to ISO26262.
The Arm® Cortex®-M0+ MCU on which the PSoC 4 HVPA-144K is based operates at up to 48 MHz with up to 128 KB of code flash, 8 KB of data flash and 8 KB of SRAM, all with ECC. The PSoC 4 HVPA-144K also includes digital peripherals such as four timers/counters/PWMs and a serial communication block that can be configured as an I2C/SPI/UART.
The PSoC 4 HVPA-144K is supported by automotive-quality software. Infineon’s Automotive Peripheral Driver Library (AutoPDL) and Safety Library (SafeTlib) are developed according to the standard automotive software development process. They are both A-SPICE compliant, following the MISRA 2012 AMD1 and CERT C, and ISO26262 compliant.
With the introduction of the PSoC 4 HVPA-144K, Infineon is laying the foundation to expand its PSoC microcontroller portfolio to include Li-ion battery management systems for EVs. The portfolio will soon include several products for monitoring and managing high voltage (400 V and above) and low voltage (12 V/48 V) batteries, further facilitating future EV adoption.
GHSP LEVERAGES ALLEGRO MICROSYSTEMS’ TECHNOLOGY TO SHIFT THE FUTURE OF ELECTRIC VEHICLES WITH THE INTRODUCTION OF NEW EVIBE SYSTEM
Technology highlights missing piece in the xEV driving equation, while also enabling broader EV market demand.
Allegro MicroSystems, Inc. (“Allegro”) a global leader in power and sensing semiconductor technology for motion control and energy efficient-system is pleased to announce, that GHSP, a global provider of mechanical and electromechanical systems and portfolio company of JSJ Corporation, is closely collaborating with and has adopted Allegro’s best-in-class gate driver and vehicle sensor technology for its new eVibe vibration enhancement system.
In the rapidly evolving world of xEV technology, there is a new class of xEV enthusiasts who crave a more immersive motoring experience. GHSP’s eVibe system transforms xEV driving by providing drivers with the noise and vibrations that mimic the familiar feel and sounds of a traditional internal combustion engine. At the heart of this next-level technology, is Allegro’s A89500 motor driver and APS12215 Hall-effect latch, which provide best-in-class performance and switching capabilities.
“From the beginning, our challenge has always been to create a solution that would address a unique and growing xEV market segment,” said Dan Dawiedczyk, President of GHSP. “We are excited to collaborate and combine our industry experience and expertise, to help bring our vision to life. Together, Allegro and GHSP are developing groundbreaking innovations. We look forward to a winning partnership for many years to come."
Helping to elevate the end product, Allegro’s A89500 motor driver allows for high power density and fast switching to help provide instant response and feel. Its transient robustness and wide input voltage range make it a standout solution in the market. The APS12215 Hall-effect latch, on the other hand, provides high-temperature performance and stable switching capabilities, enabling the eVibe system to precisely track and monitor the position of the motors' unbalanced weights, ultimately leading to a more realistic vibration experience. The eVibe technology allows several applications including ADAS, ICE emulation, or high performance.
“For more than a decade, Allegro has worked closely with market-leading automotive partners to develop innovative solutions that help shift the future of driving, power and performance in electric vehicles,” said Suman Narayan, Allegro’s Senior Vice President, Products. “Our latest collaboration highlights a new, growing market segment and demand for Allegro’s technology. We value GHSP’s automotive expertise and look forward to our continued partnership as we develop solutions that drive innovation.”
The impact of eVibe extends beyond just the driving experience. It represents a shift towards the future of xEV technology and the way owners engage with their vehicles. From mimicking an idle feel to simulated engine throttle and high-speed gear shifts via premium vibration indicators, GHSP’s technology is providing drivers with a more immersive and connected drive. This innovation has the potential to reshape the xEV market, catering to a wider range of custom options and individual customer preferences, while also helping to further the adoption of electric vehicles.
GE&EL+ REGENERATIVE LOAD & GRID SIMULATOR NOW AVAILABLE FROM INTEPRO
Intepro Systems introduces the GE&EL+ vAC/DC SiC, from Cinergia, the most complete and versatile Regenerative AC/DC Electronic Load Converter and Grid Simulator on the market.
The GE&EL+ vAC/DC SiC offers revolutionary new regenerative AC/DC technology. Starting at 50kW the device is ideal for testing a wide range of applications, including renewable energy, power HIL (hardware in the loop), smart grids, batteries, and electric vehicles. This device is both an AC and DC grid emulator and can also works as a load. As a grid emulator, the GE&EL+ vAC/DC SiC emulates real-world electrical grids in both normal and abnormal conditions.
They can be used to simulate various aspects of the grid, such as:
This ability to create diverse grid scenarios makes the GE&EL+ vAC/DC SiC a valuable tool for a variety of applications, including development, test and evaluating the performance and compliance of grid-connected devices, such as:
Recommended by LinkedIn
Intepro Systems offers several different models of grid simulators, each with its own capabilities and power ratings. Their systems offer combined products that integrate grid simulation capabilities with electronic loads for more comprehensive testing needs.
Additional features of the GE&EL+ vAC/DC SiC grid simulators include:
The GE&EL+ vAC/DC SiC features a high switching frequency, powered by silicon carbide technology which enables it to accurately simulate the behaviour of real-world loads. The converter is also regenerative, meaning that it can feed power back to the grid, reducing energy consumption and costs.
“The GE&EL+ vAC/DC SiC is a game-changer for the test and measurement industry,” said Joe Engler, CEO of Intepro Systems. “With its unmatched versatility and performance, the GE&EL+ vAC/DC SiC is the perfect solution for engineers who need to test the most demanding applications.”
Cinergia provides cutting-edge technology that enables electrification and energy transition in different markets, including EVs, renewables, and Smart Grids. With more than 15 years of experience in the sector, at Cinergia Power Solutions focuses on continuous innovation in order to offer the most efficient and technologically advanced solutions. The GE&EL+ vAC/DC SiC is available in a variety of configurations to meet the specific needs of any application.
ELECTRIC VEHICLE FUSE OPTIONS EXPAND AS GLOBAL MARKET GROWS
Bel Fuse a leading global manufacturer of products that power, protect, and connect electronic circuits, is announcing the expansion of its fuses for electric and hybrid vehicles with a complete line of 800 V offerings, complimenting the company’s line of 500 V and 1,000 V fuses.
The fuses come in a variety of formats and mounting options and are suitable for operating temperatures between -40℃ to 100℃ with some products featuring a range of up to 125℃. Depending on the deployment use, the fuses also feature a wide range of current ratings, some as low as 5 A and others as high as 800 A.
Designed for use in battery modules, packs, junction boxes, chargers, stations, and auxiliary circuits, the fuses are being released to support the maturing electric vehicle (EV) market, especially across Europe. According to the European Automobile Manufacturers’ Association (ACEA), EV and hybrid sales are rebounding in 2024 with significant increases in key markets such as Belgium and Germany.
Bel Fuse continues to expand its offerings for both overload and short circuit protection to meet the growing global demand for electric and hybrid vehicle adoption.
TOSHIBA INTRODUCES A PAIR OF AUTOMOTIVE N-CHANNEL MOSFETS TO EXPAND RANGE
New devices in L-TOGL™ package offer excellent thermal performance.
Toshiba Electronics Europe GmbH has launched two automotive N-channel power MOSFET devices to meet the growing demand for 48V batteries and systems within automotive applications including inverters, semiconductor relays, load switches, motor drives and more.
The automotive sector requires power semiconductors that offer high levels of reliability coupled with large drain current (ID) ratings and excellent heat dissipation. This is especially true for devices used within traction inverters, battery management systems and junction boxes electric vehicles (EVs) and integrated starter generators (ISGs).
The new 80V XPQR8308QB and 100V XPQ1R00AQB are based upon Toshiba’s new U-MOS X-H process. This gives low levels of on-resistance (RDS(ON)D values of 350A (XPQR8308QB) and 300A (XPQ1R00AQB) continuously with pulsed values (IDP) of 1050A and 900A respectively.
Supporting these low values, the L-TOGL™ package adopts a thick copper (Cu) clip-based leadframe structure that thermally and electrically connects the MOSFET die to the package leads. This reduces the package resistance by approximately 70% and channel-to-case thermal impedance (Zth(ch-c)) by 50% compared with the TO-220SM(W) package. Together, the process and clip reduce losses and heat generation while creating a very thermally efficient solution.
Furthermore, the L-TOGL package uses compliant gull-wing leads which reduce mounting stress and improve the reliability of solder joints. It helps to ensure ECU reliability in automotive applications with harsh temperature conditions. Both devices are AEC-Q101 qualified for automotive applications.
MOSFETs are often connected in parallel to increase current capability – especially in automotive applications. To perform effectively, the MOSFET specifications must be closely matched, so Toshiba offers to ship devices grouped to within 0.4V based upon their gate threshold voltage.
Toshiba now offers four MOSFETs housed in the innovative L-TOGL package, including Toshiba’s two existing 40V products, XPQ1R004PB and XPQR3004PB. Toshiba provides suitable products for automotive applications that increasingly require heavy currents, high power density, and excellent levels of robustness.
In conclusion, the symbiotic relationship between the electronics and automotive industries is propelling the electrification of transportation forward at an unprecedented pace. The manufacturing of key EV components within the electronics sector underscores the vital role technology plays in shaping a cleaner, more sustainable future.
As we continue on this trajectory, collaboration, innovation, and investment will be paramount. By leveraging the expertise of the electronics industry, we can overcome manufacturing challenges, drive down costs, and enhance the performance and reliability of EVs.
With each technological advancement and manufacturing breakthrough, we inch closer to a world where electric mobility is not only the norm but also a catalyst for positive environmental change. Through continued research, development, and adoption of cutting-edge technologies, we can accelerate the transition to electric transportation, paving the way for a greener, more efficient tomorrow.