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ELECTRICAL POWER SEGMENT SOLUTIONS FOR POWER MANAGEMENT BU
EV/HEV – e-MOBILITY
Public
Internal
Confidential
The famous 1900 Löhner-Porsche first hybrid electric vehicle
Updated 2017-03-23
Mersen EV/HEV presentation – Updated 2017-03-23 3
2016 KEY FIGURES
€764 M* WORLD
N°1 & N°2
36 % NORTH AMERICA
34 % EUROPE
30 % ASIA AND REST OF THE WORLD
SALES LEADERSHIP
POSITIONS STAFF
* At December 31, 2016
6,110*
PRESENCE IN 35 COUNTRIES GRAPHITE-BASED ANTI-CORROSION EQUIPMENT
BRUSHES AND BRUSH-HOLDERS FOR INDUSTRIAL ELECTRIC MOTORS
HIGH-TEMPERATURE ISOSTATIC GRAPHITE APPLICATIONS
PASSIVE COMPONENTS FOR POWER ELECTRONICS
INDUSTRIAL FUSES
Mersen EV/HEV presentation – Updated 2017-03-23 5
EP SEGMENT PRODUCT PORTFOLIO OVER 2 BUS
Electrical Protection & Control
LV GP Fuses Fusegear
MV GP Fuses
Surge Protection
High Power
Switches
Power
Rail Vehicle
LV Switches
PV Energy
Management
Solutions for Power Management
Special purpose / Semiconductor protection Fuses
Cooling
Busbar
Mersen EV/HEV presentation – Updated 2017-03-23 7
Crystal Growth Wafering Polishing
Crystal ingot Wafer
Front-End
Packaging
Binning, pick-and-place Packaging, Housing
Lithography, deposition, etching, metallization… Bare-die
Diode, IGBT, Thyristor
Applications
Silicon, SiC, GaN…
Discrete
Power module
Power Converter
Passives
SPM WITHIN MERSEN EP SEGMENT REFERS TO PASSIVE COMPONENTS, ASSEMBLED WITH POWER
SEMICONDUCTOR DEVICES OR BATTERY CELLS TO CONVERT, MANAGE AND STORE ELECTRICAL ENERGY
Battery Pack
Battery cell Battery Module
Assembly
Val
ue
-Ch
ain
Tra
ck 1
V
alu
e-C
hai
n T
rack
2
Assembly
Mersen EV/HEV presentation – Updated 2017-03-23 8
SPM PLAYGROUND: MED & HIGH-POWER APPLICATIONS
<1kW
10kW
100kW
1MW
1,200V 600V 1,700V 3,300V 6,500V
Po
we
r
Power Module Voltage Rating
Transportation Traction / Marine
White Goods. Consumer
10kV+
10MW+
PV Inverter
UPS & Motor Drives
Wind Turbine
Electrical Grid
Medical EV/HEV, Buses, Trucks
& Battery Charger
Ene
rgy
Sto
rage
Mersen EV/HEV presentation – Updated 2017-03-23 9
57%
OUR APPLICATIVE MARKETS IN SPM
Industrial Heavy Industry Plant (Paper, Steel, Alu, Oil & Gas...)
Light Industry Plant
Electricity Production & Distribution Solar
Wind mill
HVDC/FACTS
Electrical Energy Storage
Hydro / Gas
Transportation Railway
Aeronautic
Automotive
Marine
Commercial, Communication & Others Medical
Data Centers
Broadcast
Semiconductor Process
Defense
LED
Others (inc. Multiple end-use segments)
21%
20%
2%
Mersen EV/HEV presentation – Updated 2017-03-23 10
MERSEN Solutions for Power Management offer:
A global and dedicated manufacturing footprint
Bangalore, India
~ 60 pers.
Saint-Bonnet, France
~425 pers. La Mure, France
~ 55 pers.
Toronto, Canada
~ 80 pers.
Juarez, Mexico
~700 pers.
Shanghai, China
~ 170 pers.
Angers, France
~ 100 pers.
Tunis, Tunisia
~ 200 pers.
Cooling
Busbar
Fuse / Hybrid
Rochester, USA
~110 pers.
Our quality systems:
• ISO 9001
• ISO 14001
• IATF 16949 pending
• UL, IEC, CCC
• RoHS
• Controlled Goods
Standard (Canada)
• IRIS (Railway)
• EN9100 (Aeronautics)
• ITAR (US military)
Mersen EV/HEV presentation – Updated 2017-03-23 12
EV/HEV MARKET SEGMENT PERFORMANCE ADDED-VALUES
Duty-cycle severity (Request for fast charge/discharge)
Ele
ctr
ic P
ow
er
Low
Bubble diameter: relative market size by 2020
Sport
car
e-bus
e-truck
Premium
Luxury
Car
Non-premium
Car HEV
High
10kW
200kW
100 kW
BEV
HEV
BEV
HEV
BEV
HEV
BEV
HEV
Non-premium
Car BEV
> 250kW
Cable or PCB
electric connections
Standard cooling technology
Standard fuse technology
Busbar electric connections
Improved cooling technology
Advanced fuse technology
Laminated Busbar connections
Advanced cooling technology
Advanced DC over current
protection technology
Mersen EV/HEV presentation – Updated 2017-03-23 13
WHAT MERSEN PRODUCT FOR WHAT FUNCTION IN EV?
PDU: Power Distribution Unit
BDU: Battery Disconnect Unit
MSD: Maintenance Safety Disconnect
OCPD: Over Current Protection Device
SPD: Surge Protection Device
Cooling Plate
Module Fuse
Monitoring Busbar
Battery Pack / BDU / MSD
DC fuse
Auxiliaries Hybrid OCPD
Main Hybrid DC
Power Relay
Inverter / PDU
SPD
Charging Station
Fuse
Cooling
Busbar
Illustration courtesy of Renault™
Cooling
Busbar
Battery Module
Mersen EV/HEV presentation – Updated 2017-03-23 15
SMART MONITORING BUSBAR TO HANDLE BOTH HIGH POWER AND
SMALL SIGNAL IN A SINGLE CONNECTION SOLUTION
ALL-IN-ONE CONNECTION SOLUTION: Connect Li-ion or supercap cells together
Monitor small signals such as Individual cell voltage
Local temperature
CUSTOMER’S BENEFITS: Ease assembly process
No wiring errors
Reduced voltage drop
Increase current carrying capability
High resistance to shocks and vibrations
Mersen EV/HEV presentation – Updated 2017-03-23 16
WATER-COOLED BUSBAR TO HANDLE CRITICAL THERMAL
APPLICATIONS
TEMPERATURE RISE MANAGEMENT FOR: Battery modules
Capacitor bank
High power density inverter
CUSTOMER’S BENEFITS: Hot-spot elimination
Dielectric extended life-time
Metal cost saving (can use thinner copper)
Mersen EV/HEV presentation – Updated 2017-03-23 17
MERSEN BUSBAR IN EV/HEV INDUSTRY MERSEN SMART-BUSBAR IN MERCEDES S400 HYBRID
39 cells in series, 4 thermal
sensors, voltage sensor on
each cell
Mersen EV/HEV presentation – Updated 2017-03-23 18
MERSEN BUSBAR IN EV/HEV INDUSTRY MERSEN LAMINATED BUSBAR FOR BOSCH / PORSCHE 918 SPYDER BATTERY PACK
385 VDC battery pack, 6.8 KWH, up to 600A peak
Mersen EV/HEV presentation – Updated 2017-03-23 19
Every smart busbar includes: • 6 temperature sensors
• 5 voltage sensors
Temperature sensors Small signal
connector
Copper bar
2 mm
PET dielectric
MERSEN BUSBAR IN EV/HEV INDUSTRY MERSEN BUSBAR IN EV TRUCKS (15 TONS / 400VDC)
Mersen EV/HEV presentation – Updated 2017-03-23 20
MERSEN BUSBAR IN EV/HEV INDUSTRY MERSEN BUSBAR FOR SUPERCAPACITOR BANK IN STATIONARY STORAGE
BUSBAR FOR 4X5 CELLS
TIN PLATED
54V
150A
-40/+65°C
LASER WELDING
EASY OF INSTALLATION
Mersen EV/HEV presentation – Updated 2017-03-23 21
LBB DESIGN: A COMPLETE SIMULATION TOOL-SET
MECHANICAL SIMULATION
Optimization of part placement to save space in the
final assembly
Ensure mechanical constraints of heterogonous
materials
ELECTRICAL SIMULATION
Contact routing to meet clearance & creepage
Current distribution compliant with admissible current
density (A/mm²) to limit self-heating
Inductance simulation
THERMAL SIMULATION
Current flow heating-up by Joule effect in the
conductors
Power Modules create hot-spots at top terminals level
Prevent too many heat at capacitor ends
Current distribution
T° increase
Mersen EV/HEV presentation – Updated 2017-03-23 23
THREE COOLING TECHNOLOGIES
To meet customer’s needs at the closest
Air Cooling
Liquid Cooling
Phase-Change
Cooling
Th
erm
al
res
ista
nc
e
Mersen EV/HEV presentation – Updated 2017-03-23 24
THREE CORE INDUSTRIAL KNOW-HOW TO MANUFACTURE BEST-IN-
CLASS COOLING PRODUCTS
Vacuum brazing: a key step
to seal our liquid cold-plates
• High thermal performance in a
monolithic piece
• Perfect water-tightness
guarantee
• High pressure withstanding (70
bars and up!)
• No risk of corrosion
• Long lifetime > 20 years
Swaging: a cost-effective
and reliable technology for
heat-sink fins assembly
• Increase heat transfer surface
area over extruded profiles
• Swaged heat sinks offer 14%
performance increase over
glued fin solution
• Different standard spacing are
developed to address
challenging thermal applications
Heat-pipe assembly: a
phase-change technology for
most-demanding applications
• High thermal performance
• Temperature homogeneity for
power module baseplates
• Instant cooling
• Smoothen temperature peaks
• Maintenance-free
Mersen EV/HEV presentation – Updated 2017-03-23 25
MERSEN COOLING IN EV/HEV INDUSTRY MERSEN COOLING-PLATE FOR SIEMENS ELFA HYBRID-BUS DRIVES
Liquid cooling plate for hybrid-bus 50 KW to 180 KW motor inverter
Mersen EV/HEV presentation – Updated 2017-03-23 26
CHINESE MANUFACTURER
PASSENGER CARS
PIN FIN PLATES TO COOL DOWN 24 CELLS SINGLE-SIDED
4 PLATES PER BATTERY PACK PER CAR
BRAZED CONNECTORS
MERSEN COOLING IN EV/HEV INDUSTRY MERSEN COOLING PLATE FOR EV BATTERY PACK
Mersen EV/HEV presentation – Updated 2017-03-23 27
COOLS DOWN 12 CELLS ON EACH PLATE
CHINESE CAR MANUFACTURER
6 PLATES PER PACK PER CAR
MERSEN COOLING IN EV/HEV INDUSTRY MERSEN COOLING PLATE FOR EV BATTERY PACK
Mersen EV/HEV presentation – Updated 2017-03-23 29
DC PROTECTION AT MERSEN: 3 TECHNOLOGY PATHS
Monolithic
technology Hybrid technology
Product range
Core technology DC-Fuse Pyro + clearing elements Semiconductor +
Switch
Value-proposition
Ultra fast-acting fuses
(for large fault currents)
Cost-effective & proven
technology
DC specific design
Fast-acting protection < 1ms
Low-cost technology
Close-to-zero conduction loss
Operates for small or large fault current
Fully configurable
Very compact size
High cycling performances
High inrush current capabilities
Fast-acting protection
Close-to-zero conduction
loss
Fully configurable
Resettable
Arc-less
Visuals
χs series
χp series
EVpack-fuse M-fuse
Mersen EV/HEV presentation – Updated 2017-03-23 30
TYPICAL EV/HEV PROTECTION TOPOLOGY AND DEVICES
Main battery pack 1 to 16 battery modules assembled in series/parallel
(1 fuse per module up to 16 fuses) Maintenance Safety
Disconnect MSD (1 fuse + DC contactor)
Inverter + Motor
Junction Box /
Battery Disconnect Unit BDU (4 to 8 fuses)
48 V / module
Up to 200 A / module
450 1,000 V
10 200 A
450 1,000 V
Up to 800 A
450 1,000 V
Up to 800 A
~30A
~30A
~20A
~125A
~30A
M-fuse ®
EVpack-fuse ®
χp series ®
χs series ®
χs series ®
EVpack-fuse ®
Mersen EV/HEV presentation – Updated 2017-03-23 31
600 800 300 150 450 In (Amp)
400
200
600
100
300
500
48
1000
800
1200
700
900
1100
V (
Vo
lt)
3 FAMILIES OF PROTECTION AND OPERATION DEVICES FOR DC
APPLICATIONS
Battery Module Protection
EVpack-fuse
M-fuse
EV Battery Pack fuse Protection
MSD / BDU / Junction Box
χs series
χp series
Hybrid DC
protection
Hybrid DC power relay
Mersen EV/HEV presentation – Updated 2017-03-23 32
4 DC FUSE SERIES FOR BATTERY PROTECTION
600 300 150 450 In (Amp)
400
200
600
100
300
500
48
1000
800
700
900
MEV70 series 700 VDC – 35 to 600 Amp
Vo
ltag
e
(Vo
lt)
MF series 100VDC. 50 to 200A
MSD / main Fuse BDU /
Aux. Fuse
MEV100 series 1,000 VDC - 8 to 600 Amp
MEV55 series 550 VDC – 5 to 50 Amp
Battery Module Fuse
MEV70V series:
Designed for
large inrush
current
EVp
ack
-fuse
M-fu
se
Mersen EV/HEV presentation – Updated 2017-03-23 33
9 FUSE PRODUCTS LINE-UP FOR BATTERY DC PROTECTION
600 300 150 450 In (Amp)
400
200
600
100
300
500
48
1000
800
700
900
Vo
ltag
e
(Vo
lt)
MFxxA / MFxxB 50 200A
MEV100A
50 300A
ME
V1
00
C
8
30
A
MEV100J
350 600A
MEV70A
50600A MEV70V
35175A*
ME
V5
5C
5
30
A
MEV55S
160500A
*: MEV70V. Specifically designed for large inrush current
Mersen EV/HEV presentation – Updated 2017-03-23 34
MERSEN HAVE BEEN DESIGNED TO MATCH DC CONTACTOR
OPERATION. MBC VALUE MATTERS…
Matching DC contactor with DC fuse is not trivial.
Contactors offer a limited max. breaking capacity value
beyond which the fuse must clear the circuit in the
eventuality of a default . Typical matching scheme looks
like:
EVPACK-FUSE line-up has been designed to protect DC
contactors, offering MBC values <3kA over the full range.
EVpack-fuse
Default
current
DC contactor
operation Mersen operation
Inominal
Typ: 300A
Imax default
6kA and up
Imax contactor
Typ. 3kA for a few msec. Has to match with
fuse MBC value (Minimum Breaking Capacity)
EVpack-fuse
Mersen EV/HEV presentation – Updated 2017-03-23 35
χP : HYBRID OVER CURRENT PROTECTION DEVICE
The Xp system is composed by fast acting pyro element, controlled by a gate
current, plus a parallel clearing element
This protection meets custom requirements of very fast operating time and
very high overload current
Main features and Benefits
DC application focused design
Extremely low watt losses (~20W / 400A)
Excellent cycling performance
Ultra-fast acting (300 µs)
Small footprint
Large inrush current: 15 In for 100 ms
Self-triggered and/or external triggering
Tunable Time-Current curve and Minimum Breaking Capacity (MBC) value
Electric data – main circuit
Nominal Voltage Up to 1,000 VDC
Nominal Ampere In Up to 800 A
Max breaking capacity 15 kA @ 1000 VDC with L/R = 2 ms
L/R max 5 ms
Power dissipation at In 20W @ 25°C
Gate Control current 2A – 10A (2ms)
Gate Control resistance 2.2 Ω
Temperature range -40°C to +90°C
Mersen EV/HEV presentation – Updated 2017-03-23 36
χS EV: HYBRID DC POWER RELAY
XsEV have been engineered to provide high DC switching performances versus conventional mechanical
power relay.
XsEV provides maximum flexibility in equipment design and ultimate DC operation performance. This
Power Relay is a Hybrid technology with the capability of switching both high voltage and high current
designed specially for electrical vehicle applications.
Main features and Benefits
Designed for DC applications
Bidirectional
Arc-less
Reduced footprint & mass
Low conduction losses
Repeatable current make/break capability for resistive & inductive loads at full rated voltage and current
Enhanced cycling performances
Built-in turn ON fault detection
Electric data – main circuit
Device current polarity Bidirectional
Nominal voltage 500 / 1000 VDC (1200 VDC soon available)
Continuous current 300 A
Max. ON switching current 1000 A
Max. OFF switching current 500 / 1000 / 1500 / 2000 A
L/R max. ≤ 5 ms (for higher ratings please consult Mersen)
Overvoltage during current clearing Typ. 1400 V @ 500VDC – 2000 V @ 1000VDC
Number of cycles versus current and L/R > 20 cycles at 2000 A / 500 VDC / L/R = 0.5 ms
Lifetime (mechanical) > 100 000 cycles
Insulation resistance > 100 MΩ (initially)
Dielectric strength 3000 VDC
Internal contact gap 3 mm (2x1.5 mm)
Contact voltage drop 150 mV
Mersen EV/HEV presentation – Updated 2017-03-23 37
DC PROTECTION OFFER AT MERSEN: SUMMARY
Monolithic
technology Hybrid technology
Family DC-Fuse Pyro + clearing
elements
Semiconductor
+ Switch
Resettable Yes
Time to clear high fault current Excellent, 10 of µS Good, 100’s of µs Good, a few ms
Time to clear low fault current Slow to melt
10’s of seconds
Excellent
Down to 100’s of µs Excellent, a few ms
Cycling performance Application dependent Excellent Excellent
Conduction losses 80W (400A) 20 W (400A) 45 W (300A)
Tunable Time-Current curve Limited Yes Yes
Self-triggered Yes Yes No
χp
series
χs
series
EVpack-fuse
M-fuse