Fujitsu EV / PHV Relays · FTR-K3-WG, -PV version with 1.5mm gap is available FTR-K3-WS, ... Technology to achieve main target Technology for Arc extinguish • Wide contact gap

Copyright 2018 FUJITSU COMPONENT LIMITED

Fujitsu EV / PHV Relays

Fujitsu Components America, Inc.Fall 2018

High capacity of quick charger High voltage, high current requirement

Now up to50kW

2018Rated 150kW

2017Max. 150kW

Non-Hydrogen Gas for Low Cost & Small Size

High capacity of normal charger 3.3kW 6.6kW

Now up to 3.3kWFTR-K1 relay 16A, 250VAC

New design 6.6kWFTR-K5 relay 32A, 277VAC

2018Sample

FTR-E1

250A

FTR-B3

FTR-K5Under development

FTR-K3FTR-K1

FTR-E3Under development

0.1A 16A 32A 400A

AC load 250VAC

DC load 400~750VDC

Roadmap for EV & PHV Relays

Copyright 2018 FUJITSU COMPONENT LIMITED1

Target Relay Application (1) Relay Application


Battery

Inverter

Motor

Generator/Engine

DC

/AC

Battery UnitFTR-E3: Main switch for main battery disconnect from motor sideUnder DevelopmentFTR-E1: Pre-charge for protection from capacitor inrush

Quick Battery Charger (QBC)FTR-E3: DC-high voltage switching for disconnection from quick DC chargerUnder Development

Charger Cable BoxFTR-K3: Additional function in cable for safety operation

Quick Charger Stand

Charger Cable Box

Battery Unit

QBC

OBC

On Board Charger (OBC)FTR-E1: DC-side switching for disconnect from main batteryFTR-K1: AC-side switching for disconnect from outside AC charger

2

Relay Application


Charger Stand

Control Box Battery

Battery ControllerFTR-B3: Battery voltage monitor

Grid Power

Quick Charger StandFTR-E3: DC-high voltage switching for disconnect in quick DC chargerUnder Development

Normal Charge

AC/DC

Charger StandFTR-K3: Additional function in charger stand control box

Quick Charge

Charger Cable BoxFTR-K3: Additional function in cable for safety operation

3

Target Relay Application (2)

Application Proposed Relay Status

Relay #1 Main Switch relayFTR-E3 (250A, 450VDC class) Under development

New development(400A, 1,000VDC class)

Under development

Relay #2 Pre-Charge relay FTR-E1 (30A, 450VDC class) Mass Production

Relay #3 Quick Battery Charger(QBC) relay FTR-E3 (250A, 450VDC class) Under development

Relay #4 On Board Charger (OBC) DC relay FTR-E1 (30A, 450VDC class) Mass Production

Relay #5 On Board Charger (OBC) AC relayFTR-K1 (16A, 250VAC class) Mass ProductionFTR-K5 (32A, 250VAC class) Under development

Relay #6 Charger Cable relay(in charger cable box) FTR-K3 (32A, 250VAC class) Mass Production

(Relay #7) Battery Controller(for voltage monitor) FTR-B3 (1mA, 400VDC class) Mass Production

(Relay #8) Vehicle to Home FTR-E1 (30A, 450VDC class) Mass Production

Proposed Relays for EV & Charger Stand


Relay #1: Main Switch FTR-E3 Series

Arrangement : 1 form A (no-polarity) Contact rating : DC 450V/150A Carrying current : 150A @ +85 Enclosure : Plastic sealed type Dielectric strength : 2,500VAC (coil-contact)

2,500VAC (open contacts)

Feedback from Customers


FTR-E3 Existing project In future, 2021~

Contact rating DC 450V/150A DC 450V/250A DC 1,000V/400A

Contact life @rating 100 ops 100 ops, 1,000 ops 100 ops, 1,000 ops

Short term current NA 3,000A 6,000A~, 20,000A~

Shock resistance 10G 30G or more 30G or more

E3 Modify Ver. New Development

5

Relay #2: Pre-Charge FTR-E1 Series

Arrangement : 1 form A (no-polarity) Contact rating : DC 450V/20A, 30A (-HA) Electrical life : 75k @ DC 450V/10A

10k @ DC 450V/20A100k @ DC 450V/20A - Making

Carrying current : 40A, 1H @ +85 Enclosure : Plastic sealed type Dielectric strength : 5,000VAC (coil-contact)

2,500VAC (open contacts) Size (L x W x H) : 43.6 x 28.3 x 36.8mm Status : Mass Production (MP)


Relay #3: Quick Battery Charger FTR-E3 Series

Arrangement : 1 form A (no-polarity) Contact rating : DC 450V/150A Carrying current : 150A @ +85 Enclosure : Plastic sealed type Dielectric strength : 2,500VAC (coil-contact)

2,500VAC (open contacts)

Feedback from Customers


FTR-E3 Existing project In future, 2021~

Contact rating DC 450V/150A DC 450V/250A DC 1,000V/400A

Contact life @ rating 100 ops 100 ops, 1,000 ops 100 ops, 1,000 ops

Short term current n.a. 3,000A 6,000A~, 20,000A~

Shock resistance 10G 30G or more 30G or more

E3 Modify ver. New development

7

Relay #4: On Board Charger / DC-side FTR-E1 Series

Arrangement : 1 form A (no-polarity) Contact rating : DC 450V/20A Electrical life : 75k @ DC 450V/10A

10k @ DC 450V/20A100k @ DC450V/20A - Making

Carrying current : 40A, 1H @ +85 Enclosure : Plastic sealed type Dielectric strength : 5,000VAC (coil-contact)

2,500VAC (open contacts) Size (L x W x H) : 43.6 x 28.3 x 36.8mm Status : Mass Production (MP)


Relay #5: On Board Charger / AC-side FTR-K1 Series

Arrangement : 1 form A or C Contact rating : AC 250V/16A Electrical life : 20k @ rating, +85 Carrying current : 20A, 1H @ +85 Enclosure : Plastic sealed or flux-free Status : Mass Production (MP)

FTR-K5 Series Arrangement : 1 form A Contact rating : AC 250V/32A Electrical life : (1) 7k @ rating, +85

(2) 30k @ rating, +85 Carrying current : 40A, 1H @ +85 Enclosure : (1) Plastic sealed, (2) flux-free Status : Under Development


29.0 x 12.7 x 15.7 mm

33.3 x 16.5 x 27.5 mm

9

Relay #6: Charger Cable Box FTR-K3 Series

Arrangement : 1 form A Contact rating : AC 250V/25~32A Electrical life : 30k @ rating, +20 Enclosure : flux proof type Status : in Mass Production (MP)

Safety Standard Study

According to IEC62752* 1.8mm contact gap is required FTR-K3-WG, -PV version with 1.5mm gap is available FTR-K3-WS, -PS version with 1.8mm gap is available


30.1 x 15.7 x 23.3 mm

-WG -WS -PV -PSRating 25A 25A 32A 32AContact gap > 1.5mm > 1.8mm > 1.5mm > 1.8mm

* IEC62752: In-cable control and protection device for mode 2 charging of electric road vehicles (IC-CPD)

10

Relay #7: Battery Controller Relay FTR-B3 Series

Arrangement : 2 form C (no-polarity) Contact rating : DC 400V/1mA Electrical life : 100k @ rating, +20 Insulation resistance : 1,000M Dielectric strength : 1,500VAC (coil-contact Surge strength : 2,500V (2x10s, coil-contact Enclosure : Plastic sealed or flux-free Status : Mass Production (MP)


7.2 x 10.6 x 5.45 mm

11

Modification / Improvement Idea (FTR-E3) Target Modification of FTR-E3 RelayMain target

DC 450V/250A as contact rating > 30G as shock resistance Small size Low cost


0

20

40

60

80

100

120

140

Current carrying Shock resistance Size (volume) Target cost

Com

paris

on ra

tio [%

]

Comparison between Competitor Relay (100%)

Competitor relayExisting "FTR-E3"Target of new/modified FTR-E3

12

Technology to achieve main target Technology for Arc extinguish

Wide contact gap Permanent Magnet Cooling by Hydrogen gas

Modification / Improvement Idea (FTR-E3)


Capsule with Hydrogen gas

Technology to achieve main target Technology for Arc extinguish

Wide contact gap Permanent Magnet Cooling by Hydrogen gas Additional arc-extinguishing plate

For COST & SIZE

No plate With the plate

13

Modification / Improvement Idea (FTR-E3) Technology to achieve main target Effect of arc-extinguishing plate

By placing arc-extinguishing plate in the middle of arc route, the effect was confirmed as shorter arcing time.


Arc time: 1.79ms

200A

0A

Unable to extinguish arc

600VDC-200AWithout plate With plate

plate

600VDC-200A

14

DC Relay for Main Switch / Quick Charging


FTR-E3 Modified Version & New Development Relay FTR-E3 Modified Version: DC 450V / 250A New Development Relay: DC 1,000V / 400A

FTR-E3 Modify Ver. New DevelopmentContact rating DC 450V/250A DC1,000V/400AContact life @ rating 1,000 ops 1,000 ops

Make only 100,000 ops 100,000 opsShort term current 3,000A 20,000A~Shock resistance 30G or more 30G or more

Plan / ScheduleModified version of FTR-E3 (450V/250A) 2019 MP ()New Development (1,000V/400A) 2019 ES (Plan)

15

Fujitsu EV / PHV RelaysSlide Number 2Target Relay Application (1)Target Relay Application (2)Slide Number 5Relay #1: Main SwitchRelay #2: Pre-ChargeRelay #3: Quick Battery ChargerRelay #4: On Board Charger / DC-sideRelay #5: On Board Charger / AC-sideRelay #6: Charger Cable BoxRelay #7: Battery Controller RelayModification / Improvement Idea (FTR-E3)Modification / Improvement Idea (FTR-E3)Modification / Improvement Idea (FTR-E3)DC Relay for Main Switch / Quick ChargingSlide Number 17

Documents

Fujitsu EV / PHV Relays · FTR-K3-WG, -PV version with 1.5mm gap is available FTR-K3-WS, ... Technology to achieve main target Technology for Arc extinguish • Wide contact gap