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HV Capacitors in Automotive & Industry
Application
Agenda
• High voltage > 250V
• Dielectric must withstand the voltage at elevated
temperature
• Electrodes carry high ripple current - low ohmic resistance
• Reliable - 24/7 operation over years
• Design most often for long life operation
End of Life
• No standard
• Capacitor is out of specified parameters
• In general : Capacitance and/or ESR
• Limits are supplier specific
• 20% or 30% capacitance drop
• 2x or 3x ESR increase
• AND / OR relation
DC-Link Aspects
DC-Link Application
Film Lytic MLCC
Capacitance 130/27µF 11.000µF 220/33nF
Voltage 450/1100V 500V/(600V) 500/1700V
Temperatur 125°C/(170°C) 85°C/105°C/150°C 150°C
Switching Frequ
ency
60kHz 10kHz 1MHz/(9MHz)
FIT (½ Un,40°C) 2 12 3
How much capacitance we need?
10kHz 100kHz 1MHz
1kW 14µF 1,4µF 140nF
15kW 210µF 21µF 2,1µF
50kW 700µF 70µF 7µF
Assume U_max = 360V and U_max = 440V
PV equation
Stress for capacitors
1. n = voltage stress
2. Ea = activation energy
Inverse Power law : Electrical field apply a force on a charged atom
Arrhenius : accelerated move of particles
T1, T2 in [°K] and k in [eV]
Live in Space …
• The stretch is 20% in voltage, temperature and lifetime
• BUT T_max need to be considered
Lifetime calculation - C4AE
• Vr = 900V → V_upper = 1,3*Vr = 1170V
• Lifetime is equal for 1170V@70°C and 900V@90°C
900V
30kHrs
Lifetime calculation - C4AE / 900Vr
• Lifetime is equal for 1170V@70°C and 900V@90°C
30kHrs
900V * 1,3 = 1170V
C4AE Main product parameters
• T_hotspot = T_ambient + T_selfheating
• ESR is frequency dependent, lower for higher frequencies
• Rth depends on surface-area, construction and material
Electrolytic Lifetime Calculator(1)
• ALS40/41 - 9000h/105°C
Electrolytic Lifetime Calculator(1)
Electrolytic Lifetime Calculator(2)
3 harmonics
Electrolytic Lifetime Calculator(3)
5 harmonics
Impact of the harmonics
• Determine harmonics for non-sinusoidal waveforms
• Nominal Lifetime is 9000h@105°C and Vr = 900V
• Result doesn’t change much after 3rd harmonics
NoOfHarmonics LOP/h Change / %
1 15770 100 %
3 11190 71,0 %
5 11150 70,7 %
Dynamic thermal model
17
Dynamic thermal model,Thermal simulation
Calculation of operational life (Lop)
2000V / 4 capacitors à 500V
Worst case
• C1 = Cnom -20%
• C2 = C3 = C4 = C-nom +20%
Nominal Worstcase
500 667
500 444
500 444
500 444
Worst case calculation
• in general
• Example 2000V / 4 capacitors each 500V 20% tolerance
• Approximately 25% overvoltage
how many chips needed?
22
Chips
23
WITY = what Is important to you(customer)
24
on the first view - standard conditions
• 1000V rated voltage / Working frequency = 140kHz @RT
• X7R offers 4x capacitance of C0G
C0G X7R
5,5nF 20,45nF
second view - @ 840V DC-Bias
• 840V application and 1000V rated voltage
• C0G has a similar capacitance - X7R drops by 75%
C0G X7R
5,5nF 5,6nF
Impedance and ESR
• ½ the ESR
C0G X7R
373mΩ 706mΩ
10x ripple current
• Same cap, size and VR leads to more layers for C0G
• more Ni electrode layers leads to better cooling
C0G X7R
1,53A 0,11A
Ripple current over frequency
29
Vertical vs. Horizontal: convection
Heat dissipation in Air
Heat dissipation
to the Cu board.
12ARMS@140kHz
Summary
• The application somehow determine the technology
(traditional 10kHz or WideBand Gap 100kHz)
• Ceramic is suitable for WBG due high SRF
• Higher application voltage need:
• Filter or ceramic
• Aluminium capacitor bank
• Film - Lifetime can be adjusted around 20% voltage and T
• Ceramics C0G perform better than X7R
• Upright ceramic chips improve thermal behavior
• For non sinusoidal waveforms 3 harmonics are sufficient
Thank You!
Axel Schmidt
Field application Engineer
Cell +49 172 89 25 284
email: AxelSchmidt@kemet.com
Hermann-Köhl-Str. 2
86899 Landsberg am Lech
Germany
www.kemet.com

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High Voltage Capacitors Webinar

  • 1. HV Capacitors in Automotive & Industry Application
  • 2. Agenda • High voltage > 250V • Dielectric must withstand the voltage at elevated temperature • Electrodes carry high ripple current - low ohmic resistance • Reliable - 24/7 operation over years • Design most often for long life operation
  • 3. End of Life • No standard • Capacitor is out of specified parameters • In general : Capacitance and/or ESR • Limits are supplier specific • 20% or 30% capacitance drop • 2x or 3x ESR increase • AND / OR relation
  • 5. DC-Link Application Film Lytic MLCC Capacitance 130/27µF 11.000µF 220/33nF Voltage 450/1100V 500V/(600V) 500/1700V Temperatur 125°C/(170°C) 85°C/105°C/150°C 150°C Switching Frequ ency 60kHz 10kHz 1MHz/(9MHz) FIT (½ Un,40°C) 2 12 3
  • 6. How much capacitance we need? 10kHz 100kHz 1MHz 1kW 14µF 1,4µF 140nF 15kW 210µF 21µF 2,1µF 50kW 700µF 70µF 7µF Assume U_max = 360V and U_max = 440V
  • 7. PV equation Stress for capacitors 1. n = voltage stress 2. Ea = activation energy Inverse Power law : Electrical field apply a force on a charged atom Arrhenius : accelerated move of particles T1, T2 in [°K] and k in [eV]
  • 8. Live in Space … • The stretch is 20% in voltage, temperature and lifetime • BUT T_max need to be considered
  • 9. Lifetime calculation - C4AE • Vr = 900V → V_upper = 1,3*Vr = 1170V • Lifetime is equal for 1170V@70°C and 900V@90°C 900V 30kHrs
  • 10. Lifetime calculation - C4AE / 900Vr • Lifetime is equal for 1170V@70°C and 900V@90°C 30kHrs 900V * 1,3 = 1170V
  • 11. C4AE Main product parameters • T_hotspot = T_ambient + T_selfheating • ESR is frequency dependent, lower for higher frequencies • Rth depends on surface-area, construction and material
  • 12. Electrolytic Lifetime Calculator(1) • ALS40/41 - 9000h/105°C
  • 16. Impact of the harmonics • Determine harmonics for non-sinusoidal waveforms • Nominal Lifetime is 9000h@105°C and Vr = 900V • Result doesn’t change much after 3rd harmonics NoOfHarmonics LOP/h Change / % 1 15770 100 % 3 11190 71,0 % 5 11150 70,7 %
  • 18. Dynamic thermal model,Thermal simulation Calculation of operational life (Lop)
  • 19. 2000V / 4 capacitors à 500V
  • 20. Worst case • C1 = Cnom -20% • C2 = C3 = C4 = C-nom +20% Nominal Worstcase 500 667 500 444 500 444 500 444
  • 21. Worst case calculation • in general • Example 2000V / 4 capacitors each 500V 20% tolerance • Approximately 25% overvoltage
  • 22. how many chips needed? 22
  • 24. WITY = what Is important to you(customer) 24
  • 25. on the first view - standard conditions • 1000V rated voltage / Working frequency = 140kHz @RT • X7R offers 4x capacitance of C0G C0G X7R 5,5nF 20,45nF
  • 26. second view - @ 840V DC-Bias • 840V application and 1000V rated voltage • C0G has a similar capacitance - X7R drops by 75% C0G X7R 5,5nF 5,6nF
  • 27. Impedance and ESR • ½ the ESR C0G X7R 373mΩ 706mΩ
  • 28. 10x ripple current • Same cap, size and VR leads to more layers for C0G • more Ni electrode layers leads to better cooling C0G X7R 1,53A 0,11A
  • 29. Ripple current over frequency 29
  • 30. Vertical vs. Horizontal: convection Heat dissipation in Air Heat dissipation to the Cu board. 12ARMS@140kHz
  • 31. Summary • The application somehow determine the technology (traditional 10kHz or WideBand Gap 100kHz) • Ceramic is suitable for WBG due high SRF • Higher application voltage need: • Filter or ceramic • Aluminium capacitor bank • Film - Lifetime can be adjusted around 20% voltage and T • Ceramics C0G perform better than X7R • Upright ceramic chips improve thermal behavior • For non sinusoidal waveforms 3 harmonics are sufficient
  • 32. Thank You! Axel Schmidt Field application Engineer Cell +49 172 89 25 284 email: AxelSchmidt@kemet.com Hermann-Köhl-Str. 2 86899 Landsberg am Lech Germany www.kemet.com