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.
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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
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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
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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.
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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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