Automotive

Ferrites in Automotive,

EVS and HEVSwww.ferroxcube.com

•Lowcorelossesatw

orkingfrequencyandtemperaturetoachieve

highefficiency•Switchingathigherfrequenciesallow

ssizeandcostreductionofthemagneticcom

ponents•Lowprofileshapesarerecom

mendedtobuildcom

pactandmodular

designs

FERROXCUBEisamemberoftheYageoGroup,whichisamongtheworld'sstrongestsuppliersofhighqualitypassivecomponents.Asaleadingsupplierofferritecomponents,FERROXCUBEhasmanufacturingoperations,salesoffices,andcustomerservicecentersallovertheworld.Wesupplyoneofthebroadestrangesofhigh-quality,innovativeproductsandplacestrongemphasisonminiaturizationofmagneticfunctions.FerritecomponentsandaccessoriesfromFERROXCUBEareusedinawiderangeofapplications,fromtelecommunicationsandcomputingelectronicsthroughconsumerelectronicproductstoautomotive.

Powerconversioninhybridandelectricvehicleshasledtonewtechnicalchallengesintheautomotivefield.Whenitcomestopowerconversionsystems,magneticdesignhasagreatimpactnotonlyonefficiency,butalsoonweightandcost.FerroxcubeoffersawidevarietyofcoresfortransformersandinductorsinAutomotive&e-Mobility,optimizedfordifferentconditionsoffrequencyandtemperature.

3

IntroductionGear Up for Automotive ApplicationsPowerconversioninhybridandelectricvehicleshasledtonewtechnicalchallengesintheautomotivefield.Currently,highvoltagebatteriessupplythepowertothemotoraswellastootherelectronicdevices.Severalstagesandtypesofenergytransformationarerequired.

Whenitcomestopowerconversionsystem,magneticdesignhasagreatimpactnotonlyonefficiency,butalsoonweightandcost.Applicationsofferritesinhybridandelectriccarsarecountless.ThisapplicationnoteshowsthevarietyofFerroxcube’sshapes,sizesandmaterialsthatcanbecombinedtoachievethehighestefficiencyinapowerconversionsystemdesignforhybridandelectricvehicles.

Asaleadinginnovatorinferrite-ceramictechnology,Ferroxcubeoffersadvancedmaterialinawidevarietyofcoreshapesfortransformersandinductorsinautomotiveandelectronicvehicleapplications.Ourproductsareoptimizedfordifferentconditionsoffrequencyandtemperature.Recommendedshapes,sizesandgradesareintendedtosupportthemaindesignconsiderations.

Requirements for Automotive Applications• Lowcorelossesatworkingfrequencyandtemperaturetoachievehighefficiency• Switchingathigherfrequenciesallowssizeandcostreductionofthemagneticcomponents• Lowprofileshapesarerecommendedtobuildcompactandmodulardesigns

Access Control

• PassiveEntry,PassiveStart

Lighting

• LEDLighting

• HIDHeadlights

• LEDHeadlights

Common for EVS & HEVS

• DC/DCBattery

• Interchanger

• BoostCharger

• Inverter

Power Train

• FuelInjectorBoost

• StopandGo

Plug-in & Electric

• BatteryCharger

• WirelessCharger

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3C96High efficiency, operation up to 400 kHz, high power density

Automotive Application Matrix

Function Material Grade Preferred Core Shape Characteristics

Access Control

Passive Entry Passive Start On-board antenna 3C90, 3C91, 3C95 Long Bar Temperature stability

Key antenna X Y axis 4A11, 4A5 Small bar

Key antenna Z axis 4A11, 4A5 Drum

Key antenna 3D coil 4A11, 4A5 Multiwinding core

Lighting

LED Daylight, Signaling & Convenience

Inductor in the LED driver 3C95, 3C92 4F5 (in development)

Drum cores High saturation

LED Headlights High Power Inductor in the LED driver

3C92, 3C97 3F36

Low profile compact mid size Low losses, high saturation

HID Headlights A transformer to generate high voltage for ignitor

3C92, 3C97 3F36

Compact planar or mid size cores (Planar E32, RM8, PQ20..)

Low losses, high saturation

Power Train

Fuel Injector Boost A boost inductor for the DC/DC converter to generate overvoltage

3C92 PQ32 High saturation

Stop and Go A boost inductor for the DC/DC converter to generate overvoltage

3C92, 3C97 PQ, RM, EE High saturation, low loss

EV & PHEV battery charger

EMI filter Common mode choke 3E10, 4S2 Mid-large size toroids

PFC Inductor 3C92 PQ35, RM14 High saturation

DC/DC converter to battery voltage

Transformer provides isolation between grid and automotive

3C95, 3F36 Planar and compact sizes: ER41

Inductor 3C92, 3F36 Planar and compact sizes: ER41

IGBT isolation transformer 3C95, 3F36 Small EP or planar Low losses

Wireless Charger Emitter coil (ground unit) 3C90, 3C95 Large plates Temperature stability

Receiver coil (vehicle unit) 3C90, 3C95 Large plates Temperature stability

Auxiliar DC/DC to drive IGBT’s circuitry

Inductor 3C95 Planar ER23 Low loss

Current Sensing Current transformer 3E27 Toroids High perm., temp and B stable

Hall sensor 3E27, 3E10 Toroids High perm., temp and B stable

HEV, EV, PHEV

DC/DC bidirectional HV battery to 12 V battery

Transformer provides isolation between HV and low voltage

3C95, 3F36 Planar and compact sizes: ER41 Low loss

Inductor 3C92, 3F36 Planar and compact sizes: ER41 High saturation

Auxiliar DC/DC to drive IGBT’s circuitry

Inductor 3C95 Planar ER23 Low loss

Current Sensing Current transformer 3E27 EP, toroids High perm., temp and B stable

Hall sensor 3E27 Gapped toroids, UU, custom High perm., temp and B stable

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FerritesforadvancedautomotiveelectricalsystemsAccess control: Passive Entry Passive Start (PEPS)PassiveEntryPassiveStartsystemsarebasedon2frequencies:aUHFdatacarrierthattransmitsencryptedcodesandalowfrequency(125-134kHz)signalthatstartsthetransmission,wakingupthekeywhenthedrivertouchesanyofthedoors.Theselowfrequencysignalsareemittedbyferriteantennaslocatedinseveralplacesinthecar(sides,frontandback)toensurefullcoveragearoundit,andalsointhedriverkey.Thecaremitterantennasarepowerfulenoughtoinduceacurrentinthekeyreceiverantennatowakeitup,startingthecommunicationprotocol.

TheantennasarebasedonaresonantLCcircuittunedat125kHzaccordingto:On board antennasThemostcommonshapeforthisfunctionisarectangularbarranging60to90mmlong. Tighttoleranceoninductanceisneededtokeepconstantandreliabletuning.Thiscanbeachievedby:

• Lowspreadonmechanicaldimensionsoftheferritecores,easingthewindingprocess.Ferroxcubehascapabilitiestomachineallsidesoftheproduct.

• Thermallystablematerial.Ferroxcube3C95materialoffersoptimaltemperaturestability

Optimalantennasensitivitystronglydependsonferritemateriallossfactor.FerroxcubeprovidesseveralsolutionswithhighQualityFactor(Qfactor):preferredmaterialsare3C90,3C91and3C95.

5000

50 50 2500

150

1000

2000

3000

4000

μ i

T (°C)

3C90 h a n d b o o k , h a lfp a g e10000

50 50 2500

150

2000

4000

6000

8000

µ i

T ( C)°

3C91 handbook, halfpage10000

50 50 2500

150

2000

4000

6000

8000

μ i

T ( C)°

3C95

Initial permeability as a function of temperature

h a n d b o o k , h a lfp a g e

1 10 102

104

f (MHz)

μ' ,s μ''s

103

102

1010-1

3C91

μ''s

µ' s

Complex permeability as a function of frequency

6

Key antennasThekeyneeds3antennas,oneforeachaxis,insuchawaythatdoesn’tmatterwhatthepositionofthekeyis,sothat,thefieldwillbedetected.

Theantennashavetofitinthethincreditcardsizedkey,thusalowprofileisamust.Themostcommonshapeisarectangularbar10mmlong.TheZaxisissensedwithalowprofiledrumcore.

ThepreferredmaterialsarehighresistivityNickelZincenablingthepossibilitytowinddirectlyonthecore.Ferroxcubepreferredmaterialsare4A11andtemperaturestable4A5(indevelopment).

LightingNewdevelopmentsinlightingtechnologyhaveimprovedstronglytheefficiencyofthesystems,reducingtheconsumptionandincreasingthelifetimewhencomparedwithtraditionalincandescentlamps.Butthesetechnologies,includingLEDandHIDlampsrequirespecificpowerconversionsystemsusingcurrentcontrolledLEDdriversorignitersinthecaseofHID.

LEDdriversuseaninductortostoretheenergyontheDC/DCconverter.Thereareseveralsolutionsdependingonthepower:

• LowpowerLED’s(daylight,signaling)useverycommonpowerinductors.Ferroxcubeoffersdrumcoresin4F5materialexhibitinghighsaturationfluxandlowlosses(indevelopment).

• Headlights:duetothehigherpower,itispreferredtousehighefficiencymaterialsandshapes.Ferroxcube3C92exhibitsthehighestsaturationflux(460mTat100ºC),while3C97haslowlossatalltemperatures.Forhighswitchingfrequency(>400kHz)3F36istheoptimalchoice.ThepreferredshapesarecompactPQ20orRM8coresandalsoplanarcores.

HIDignitersuseahighfrequencytransformertoboostthevoltageforthehighvoltagegeneratorgenerator.Samematerialsmaterialsandshapesarepreferred:3C92duetoitshighBsat,3C97forlowlossesandthermalstabilityand3F36for>400kHzoperationandthermalstability,usingPQ,RMandplanarcores.

h a n d b o o k , h a lfp a g e10000

50 50 2500

150

2000

4000

6000

8000

µ i

T (°C)

3C9710000

50 50 250 3500

150

2000

4000

6000

8000

μ i

T ( °C)

3C92

−50 50 2500

150

1000

2000

μi

T (°C)

3F36

Initial permeability as a function of temperature

1 10 102

104

f (MHz)

μ' ,s μ''s

103

102

1010-1

4A11

μ''s

μ' s

Complex permeability as a function of frequency

7

Auto stop and start boost converterFuelconsumptioncanbeoptimizedusingautostopandstartsystemsthatshutdowntheenginewhilethecarisstoppedandinneutral.Whentheclutchispressed,theenginestartsquicklyagainusingahighpowerstartermotor.Duringcrankingthebatteryvoltagedropsfrom12Voltsto10orevenless.AboostDC/DCconverterkeepsastablesupplytoallelectricsystems(airconditioning,radio,lights…)preventingthemfromswitchingoffduringthisdrop.

FerroxcubeoffersseveralmaterialssuitedfortheinductorinthisboostDC/DCconverter:3C92withitshighBsat(460mTat100ºC)and3C97withlowlossateverytemperaturearespeciallysuitedforoperationbelow400kHz.CommonshapesarePQ,RMandEcores.

Fuel injector boost converterFueldistributioninthecylindercanbeimprovedwhentheinjectorsarestartedwithashortovervoltage.ThisovervoltagecanbeaccomplishedusingaDC/DCboostconverterwhichismanagedbytheinjectiondriver.Ferroxcubeoffers3C92highsaturationmaterialinPQ26andothershapesforoptimaloperationoftheconverter.

8

FerritesforhybridandelectriccarsElectricalpowerconversiononhybrid,pluginhybridandelectriccarsisoneofthekeyparametersonthecarautonomyandefficiency.Electricalpowerisgenerated,storedandconsumedatdifferentlevelsandevenfrequencies.Eachoftheconversionstepsusesferritesfordifferentfunctions:energystorage,filtering,shielding,galvanicisolationortransformation.

Ferroxcubeprovideshighendcosteffectivesolutionsforallthosefunctions,supportingcustomersonoptimaldesignwhenneeded.

Mains

Common to HEV, EV

Highvoltagebattery

DC/DC(bidirectional)

Inverter(bidirectional)

Servicebattery12Volt

ACmotor

Battery Charger

EMIFilter

PFC

DC/DC

Wirelessreceiver

Wirelessemitter

OnboardsystemsPHEV,EV

Grid connected battery charger

ThisunittransformsthepowerfromthegridtohighvoltageDCtobestoredinthevehiclebattery.Thepowerrangesfrom3to20kw(orevenmore)dependingonthechargingspeed.Generallythesystemconsistsof3units:

• EMIfilter:commonmodechokespreventEMInoisegoingtothegrid.Ferroxcubeprovideshighpermeabilityandextendedbandwidthtoroidsinafullrangeofsizes.Optimalmaterialsare3E10,3E27forlowfrequency(below20MHz)EMIsuppressionand4S2forhighfrequency(upto300MHz).

• PowerFactorCorrector:highsaturation3C92withdistributedairgapcoresareoptimalforthisfunction.Customdesigniscommonlyusedtofitthecoreinthehousing.

• DC/DCconvertertobatteryvoltage:commonlyaboostconverterwithgalvanicisolation.Thepreferredmaterialsare3C95(lowlossatwidetemperaturerange,<400kHz)and3F36(lowloss,>400kHz)onboththeinductorandtransformerusingplanarorPQcores.SwitchescanbeisolatedaswellusingsmallEPorEFDcores.

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Ground fault interrupterHighpermeabilitycores(3E10,10kpermeability)canbeusedfordetectionofcurrentleakagetoground.Whenthereisamismatchbetweenlineandneutralthesecondarywindinggeneratesasignalproportionaltothemismatch,whichcanbeusedtostopthecharging.

Wireless chargerInductivewirelesschargersenablethepossibilityofchargingthecarwithoutpluggingittothegrid.Safetyisoneofthemajorbenefits:thevehicleiscompletelyisolatedfromthegrid,allowingthepossibilityoftransferringhighpowerwithouttheneedtohavealowresistancegroundconnection.

Thechargingcoilsare“shielded”withferritetilestodrivethefieldtoeachother.Ferroxcubecanprovidetilesinawidevarietyofsizesandthicknesseson3C95lowlosswidetemperaturematerialandalsoincostcompetitive3C90.

Bidirectional battery chargerThisunitexchangesenergybetweenthehighvoltagebattery(commonly200or400Volts)totheservicebattery(12Volts).ThisunitisanisolatedDC/DCbuckboostconverterhandling3kw.

Thepreferredinductormaterialsare3C92and3C95forthetransformer.Shapesaregenerallyplanarmagneticswhichcanbeeasilyparalleledandconnectedtoaheatsink,butothershapesarealsoavailable.

Auxiliary power suppliesAuxiliarypowersuppliesareusedtopowertheElectronicControlUnits(ECU)andtheswitchingcircuitry.Powercanbeobtainedfromeitherthehighvoltagebattery,orfromtheservicebattery,andreliabilityisamustforsafetyreasons.Thepreferredmaterialis3C95usingsmallormidsizecores(planarER32,PQ20).

Current sensingItispossibletouseferritecoresforcurrentsensorsin2differentways:

• Currenttransformer:onlyapplicabletoAClines.Thesecondarysuppliesacurrentproportionaltothemeasuredcurrentontheprimary.Thematerialsare3E27and3E10onsmallEPcoresortoroids.• CombinedwithaHalleffectsensor.Thesensorislocatedinthecoreairgap.BothACandDCcurrentscanbemeasured.Thepreferredmaterialsare3E27and3E10ongappedtoroidsorEcores.

Current in equals current out

Comparatorcircuit

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Preferred Materials

Power conversion materials: Low frequency

• Lowfrequency:<300kHz

• Thermalstable:3C95

• Costeffective:3C90

Power conversion materials: High frequency

• Highfrequency:>300kHz

• Improvedtemperatureperformance

EMI suppression materials

• 4S2:HighfrequencyEMIsuppression

• 3E27:HighTc,lowfrequencyEMIsuppression

• 3E10:Lowfrequency,highimpedanceEMIsuppression

Symbol Conditions Value Unit

3C90 3C91 3C95

µi 25°C ,10 kHz , 0.25 mT 2300 ±20% 3000 ±20% 3000 ±20%

µa 100°C, 25 kHz, 200 mT ≈ 5500 ≈ 5500 ≈ 5000

Bsat 25°C ,10 kHz ,1.2 kA/m ≈ 470 ≈ 470 ≈ 530 mT

10°C ,10 kHz ,1.2 kA/m ≈ 380 ≈ 370 ≈ 410

PV 100°C, 100 kHz , 100 mT ≈ 80 ≈ 40 ≈ 40 kw/m3

100°C, 100 kHz , 200 mT ≈ 450 ≈ 300 ≈ 290

ρ 25°C, DC ≈ 5 ≈ 5 ≈ 5 Ωm

TC ≥ 220 ≥ 220 ≥ 215 °C

Density ≈ 4800 ≈ 4800 ≈ 4800 kg/m3

Symbol Conditions Value Unit

3E10 3E27 4S2

µi 25 °C; ≤10 kHz, 0.25 mT 10000±20% 6000±20% ≈ 850

Bsat 25 °C; 10 kHz, 1200 A/m ≈ 460 ≈ 430 ≈ 340 mT

100 °C; 10 kHz, 1200 A/m ≈ 270 ≈ 270 ≈ 230

tanδ/µi 25 °C; 30 kHz; 0.25 mT ≤ 5 x 10-6

25 °C; 100 kHz; 0.25 mT ≤ 20 x 10-6 ≤ 15 x 10-6

ηB 25 °C; 10 kHz; 1.5 to 3 mT ≤ 0.5 x 10-3 T-1

ρ DC; 25 °C ≈ 0.5 ≈ 0.5 ≈ 105 Ωm

TC ≥130 ≥150 ≥125 °C

Density ≈ 5000 ≈ 4800 ≈ 5000 kg/m3

Symbol Conditions Value Unit

3F36

µi 25°C ,10 kHz , 0.25 mT 1600 ±20%

µa 100°C, 25 kHz, 200 mT ≈ 2400

Bsat 25°C ,10 kHz ,1.2 kA/m ≈ 520 mT

10°C ,10 kHz ,1.2 kA/m ≈ 420

PV 100°C, 500 kHz , 50 mT ≈ 90 kw/m3

25°C, 500 kHz , 100 mT

100°C, 500 kHz , 100 mT ≈ 700

ρ 25°C, DC ≈ 8 Ωm

TC ≥ 230 °C

Density ≈ 4750 kg/m3

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