ISSUE 012 Winter 2021 Sigma Powertrain EMAX transmission dossier l In conversation: David Hudson l 48 V systems focus l 2021 Battery Show North America and Cenex-LCV reports l Everrati Porsche 911 digest l Switching insight l Motor laminations focus

Renesas’ chips support fast recharging and hot-plug capability up to 62 V 48Vbattery pack support chips Renesas Electronics has launched two controller chips – the RAA489206 and the RAA489204 – for 48 V battery packs in industrial e-mobility applications (writes Nick Flaherty). The chips support packs with up to 16 cells with cell balancing up to 200 mA to support fast recharging and hot-plug capability up to 62 V. Hot-plugging allows battery packs to be safely removed while a system is still operating. The RAA489206 provides full high-side battery protection and monitoring for 4S to 16S cell packs, balancing the cells in the pack to within 10 mA and to 200 mA for the whole pack. It operates in a voltage range of 12 to 55 V with ±10 mV voltage measurement accuracy and low side- current sensing and charging/discharging protection for the high-side transistors. The RAA489204 provides daisy-chain operation to link the cells, and adds enhanced diagnostics compared with previous devices but is pin-compatible. It also includes an option for internal cell balancing as cell temperatures vary. The RAA489204 operates at up to 65 V with ±10 mV voltage measurement accuracy and ±190 mV pack voltage measurement accuracy. It provides data on all voltages, temperatures and diagnostics for 112 cells in less than 10 ms. Up to 30 devices can be used together for 48 V packs in applications such as electric forklifts. The controllers have built-in self- diagnostics to improve the functional safety for e-mobility, reducing firmware workload and easing the design burden of meeting safety standards. Renesas has developed a reference design for a battery management system that supports up to 28 cells using the chips. BATTERY CONTROL Premo’s converter integrates two magnetic components that share the same core Dual-component power converter Premo has developed an 11 kW power converter using its patented technology that integrates multiple magnetic components (writes Nick Flaherty). The 3DP-11KWHVHV combines a full- bridge 150 µH LLC resonant transformer and 25 µH resonant choke in a single unit. This cuts the volume of the converter by up to half, and can reduce the amount of ferrite material required by two-thirds. Most power converters based on resonant topologies use a separate transformer, resonant choke and output choke. Every component has its own design, core, winding and thermal dissipation solution. When power levels exceed 7 kW, heat dissipation is a key consideration. Premo’s 3DPower approach integrates two magnetic components that share the same core and feature two orthogonal magnetic fields at all points within the core. That means there is only one inductive component to consider and one mechanical drawing interface to fit and connect, increasing the reliability. 3Dpower uses CoolMag, a silicon compound compatible with the magnetic components that dissipates the heat from the top of the components to the liquid-cooling plate with a thermal conductivity of more than 1.7 W/mK. The silicon compound removes the air from the coils to improve heat dissipation. The 3DP-11KWHVHV is available with an aluminium heat sink that acts as a direct thermal interface to the cold plate, and Premo is developing a 22 kW version. Designs can be fully customised according to customer requirements. It meets the AEC-Q200 automotive quality standard and other, more restrictive customer automotive supplier standards. POWER CONVERSION Winter 2021 | E-Mobility Engineering 7 TheGrid