Analysis and Design of a High Power Density Full-Ceramic 900 V DC-Link Capacitor for a 550 kVA Electric Vehicle Drive Inverter

Cittanti, Davide; Stella, Fausto; Vico, Enrico; Liu, Chaohui; Shen, Jing; Xiu, Guidong; Bojoi, Radu

doi:10.23919/ipec-himeji2022-ecce53331.2022.9807220

Cited by 11 publications

(2 citation statements)

References 20 publications

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“…The National New Energy Vehicle Technology Innovation Center also developed an SiC inverter with a dc bus voltage 900 V in 2022, with the capacity of 550 kVA and a switching frequency of 25 kHz. Compared with the traditional design, the volume was reduced by 6.6 times, and the weight was reduced by 3.3 times [10]. However, the increase in dc bus voltage and switching frequency could exacerbate the bearing electric corrosion.…”

Section: Introductionmentioning

confidence: 99%

Research on Analysis and Suppression Methods of the Bearing Current for Electric Vehicle Motor Driven by SiC Inverter

Yang,

Cheng,

et al. 2024

Energies

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The silicon carbide (SiC) inverter brings great advantages to the motor drive systems of new energy vehicles; however, severe challenges to the bearings also happen. The high dc bus voltage and switching frequency of SiC inverter can increase the discharge frequency and energy when the bearing grease film collapses. As a result, the bearing suffers severe electric corrosion, and the service life of the motor drive system can be shortened. In this paper, the characteristics of common-mode voltage and bearing voltage are analyzed, firstly under space vector pulse width modulation (SVPWM). After that, the common-mode equivalent circuit model of the motor drive system is established. The frequency characteristics of bearing voltage are revealed, and the safe working area is determined. Then, the frequency characteristics of bearing voltage and current are verified based on IGBT and SiC inverters in experiments. After that, by designing a common-mode filter, the bearing voltage and current are significantly attenuated. Furthermore, the active zero state PWM (AZSPWM) is adopted to reduce the common-mode voltage from the inverter. At the same time, combined with the common-mode filter, the bearing voltage and current are further reduced. The experimental results show that the switching frequency has a decisive effect on the amplitude of bearing voltage and current. The bearing voltage can be attenuated to around half of the reference bearing voltage by using the common-mode filter and AZSPWM strategy, respectively. The combination of the common-mode filter and AZSPWM strategy can reduce the bearing voltage to around one-fourth of the reference bearing voltage, which can effectively reduce the breakdown time and discharge energy of the grease oil film.

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Section: Introductionmentioning

confidence: 99%

Research on Analysis and Suppression Methods of the Bearing Current for Electric Vehicle Motor Driven by SiC Inverter

Yang,

Cheng,

et al. 2024

Energies

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“…C APACITORS have been utilized as one of the most critical components in power electronics converters, such as DC-link, filters, and resonant tanks, covering a frequency range from tens-Hz to mega-Hz [1]. The multi-layer ceramic capacitors (MLCCs), as one of the most popular high energy density capacitors, has a compact format of alternatively sintering hundreds of thin (a few micrometers) layers of metal electrode and ceramic dielectric.…”

Section: Introductionmentioning

confidence: 99%

Loss Characterization and Modeling of Ferroelectric Class II Multi-Layer Ceramic Capacitors in Resonant Converters

Jiang¹

2022

Preprint

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<p>Class II multi-layer ceramic capacitors (MLCCs) employing ferroelectric materials have been widely utilized as the primary energy storage and transfer element in high-frequency resonant converters due to their ultra-high energy density. In these applications, MLCCs experience large-signal and high-frequency electrical excitations superimposed on biased voltages, burdening converters' efficiency due to their significant power loss. However, little has been published to reveal the large-signal loss characteristics of Class II MLCCs under such realistic operating conditions. This paper develops a novel characterization method to experimentally extract MLCC power loss using a resonant-Sawyer-Tower (Res-ST) circuit under large-signal and wide-frequency-range excitation with DC bias voltage. A general loss modeling approach based on Steinmetz’s Pre-electricized Graph (SPeG) is also proposed to accurately correlate the large excitation amplitude, wide-range frequency, and DC bias voltage. In this paper, the SpeG model first provides the material-specific volume loss density of four common dielectric materials and then can be easily extrapolated to evaluate the loss of the MLCCs with different rated voltage$\&$capacitance but employing the same dielectric material. In order to extend the material-specific SPeG model to device-level application, this paper also prepares an easy-to-follow tool, dielectric thickness observer (DTO), to estimate the dielectric microstructural geometry by tracking the $C$-$V$ characteristics provided in the product datasheet. The combination of the proposed loss characterization method, SPeG model, and DTO can be used as a very convenient and accurate tool to estimate the power loss of MLCCs in different applications, in particular high-frequency resonant tanks. This article is accompanied by SEM images and MATLAB code demonstrating the effectiveness of the proposed DTO.</p>

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Cost Effective 3D Printed Heatsink for Fast Prototyping of WBG Power Converters

Stella,

Savio,

Vico

et al. 2024

2024 IEEE Applied Power Electronics Conference and Exposition (APEC)

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Analysis and Design of a High Power Density Full-Ceramic 900 V DC-Link Capacitor for a 550 kVA Electric Vehicle Drive Inverter

Cited by 11 publications

References 20 publications

Research on Analysis and Suppression Methods of the Bearing Current for Electric Vehicle Motor Driven by SiC Inverter

Research on Analysis and Suppression Methods of the Bearing Current for Electric Vehicle Motor Driven by SiC Inverter

Loss Characterization and Modeling of Ferroelectric Class II Multi-Layer Ceramic Capacitors in Resonant Converters

Cost Effective 3D Printed Heatsink for Fast Prototyping of WBG Power Converters

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