Improving the environmental and driving performance of electric and hybrid vehicles with DENSO’s state-of-the-art products

Products for Electric and Hybrid Vehicles

Products for Electric and Hybrid Vehicles

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Electr ic and hybr id vehic les that reduce CO2 emissions are equipped with some specific products not found in conventional gasoline-powered vehicles. DENSO provides products including 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 combining the world’s top discharge power density with a new cooling technology that manages temperature levels in built-in semiconductor power devices*. This cooling technology is based on both radiator cool ing technologies and electronics technologies that have been developed through our in-house production of semiconductor devices.

DENSO will continue developing new technologies and products that improve the performance of electric and hybrid vehicles.

*Power devices are electronic components that act as switches to turn on and off the flow of high current.

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DC-DC Converter

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Power Control Unit

Battery Current Sensor System Main Relay

Electric Compressor

Hybrid VehicleElectronic Control Unit

Products for Electric and Hybrid Vehicles

Battery Monitoring Unit for Lithium-ion Batteries

Motor Stator

●Automakers require higher output power and smaller packaging to meet the needs of their full line-up of hybrid systems.

●DENSO has achieved a 60% increase in power density (output power per unit volume) from conventional models by dramatically improving cooling performance.

Power Control Unit

●The SMR connects and disconnects electric currents between the high-voltage battery and high-voltage system by controlling the contact of movable and fixed parts.It also shuts off the high electrical voltage in a collision to secure the safety of vehicle occupants.

●DENSO’s SMR ar ranges magnets opposite each other and lengthens the arc path al lowing the arc to be extinguished in a smaller space.

●Reduced SMR size by using an unsealed contact chamber.

System Main Relay (SMR)

●The electric compressor provides comfortable air conditioning when the vehicle is stopped.

●The world first mass-produced electric compressor with integrated inverter and motor.

●Compact size almost same as a conventional compressor.

●Minimizing mass increase for vehicle fuel/power efficiency.

●Low noise/vibration design for quiet environment.

●Three varieties covering all vehicle sizes.

Co-developed with TOYOTA INDUSTRIES CORPORATION

Electric Compressor

●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 through optimally arranged circuit elements.

DC-DC converter designed to recharge the auxiliary battery.

DC-DC Converter

Battery Current Sensor

●Simple structure.

●No printed board or soldering required.

●Input and output terminals with capacitors for improved noise reduction.

Current sensor detects the current flow and monitors the state of the main battery charge.

●The Battery Monitoring Unit is designed to precisely control the battery’s voltage in order to operate lithium-ion batteries safely and efficiently.

●Compared to a conventional voltage control method, DENSO’s new method controls the voltage of each cell and eliminates the fluctuation among the cells at a lower cost.

●Using a simple circuit, the battery monitoring unit compares each cell’s voltage with the average discharge.

●A micro-computer in the battery monitoring unit measures the voltage of each cell and detects cells which have voltage higher than the target level, enabling all cells to discharge at the same level.

Battery Monitoring Unit for Lithium-ion Batteries

ECU controls overall hybrid system in hybrid vehicles.

●Controls traction of motor and engine, HV battery, regenerative braking and other functions.

Hybrid Vehicle Electronic Control Unit (HV-ECU)

●DENSO's motor stator combines a proprietary square wire segment conductor with separated stator core. The unique stepped shape conductor results in a high power, short length, and low mass to optimize fuel economy in hybrid vehicles.

Motor Stator