電動(dòng)汽車高壓母線主動(dòng)放電與預(yù)充電技術(shù)報(bào)告-2024-12-技術(shù)資料

Tuesday,April25,2023

03:00pmCEST|EMEAsession

02:00pmEDT|Americassession

ActiveDischargeandPre-chargeofEVHighVoltagePowerBus

2

ll·fe.augmented

ActiveDischargeofEVHighVoltagePowerBus

1

WhydoweneedtodischargeHVBus?

2

HowcanwedischargeHVbus?

3

BenchmarkingDischargeSwitch

4

WhyusingTHYRISTOR?

5

6

7

8

THYRISTORProductrange

ReferenceDesignforHVBusdischarge

Howtodiagnosethedischargefunction?

LivedemoofDiagnosticandHVbusDischarge

ll·E.augmented

BMSActiveDischargewithTHYRISTOR

FastDischargepreventsFirehazard

IncriticaleventstheHVsystemshallbeactivelydischargedtopreventshortcircuitfireandelectricalshocksbyresidualvoltage.

Thebatteryvoltageisdisconnectedbyaseparatedisconnectionunit.

AllDCCapacitorsaredischargedinpowerresistorswithminimalvalueinordertominimizethedischargetime

3

SafetyRequirementinISO-6469specifydischargeinlessthan10sbutSCRDischargeinfewmillisecondswilllimittheriskofFire.

ISO6469-Part4

Postcrashelectricalsafety

400V

80

DC-Link

VOLTAGE

60

Timeto60VRDischargeCurrent

Fewms(shorterisbetter)

MinimizePowerresistorvalue

(smallerisbetter)

Batterydisconnected

VDC

SafeArea

5s

Vehiculestops

DClinkCapacitordischarge

DC-LinkVOLTAGE0V

10s

tmTime

Initialimpact

Invertercurrent

decreasetozero

(50A0A)

ll·fE.augmented

HVCapacitivedischarge

SWITCHBenchmark

FOCUS

A

G

K

IGBT/MOSFET

Close/Open

Multiple

OPEN

<100A

6.5x9.7x2.3mm

PyroSwitch

CloseSingleSHORT5000A

25x30x60mm

SwitchDischarge

FailsPeakCurrent

Size

Price

THYRISTOR

Close

Multiple

SHORT

Upto3000A

6.5x9.7x2.3mm

ll·fe.augmented

WhyusingSCRforHVdischarge?

SCRHigherpeakCurrent

MOSFET&IGBTareturnedONwithGateVoltage

MOSFETPeakcurrentwillbelimitedbySaturationregionIGBTPeakcurrentwillbelimitedbylinearMode

SCRislatchedbyGatecurrentpulse

OncetheSCRislatched,gatecurrentcanberemoved

SCRPeakcurrentismuchhigherthanMOSFETorIGBT

ForHVCapacitiveDischarge,onlySCRareabletosupport>2000A@1ms

ll·fe.augmented

WhyusingSCRforHVdischarge?

300A

2

1

3

SafeOperatingArea(IGBTexample)isdefinedby

1Collector-EmiterSaturationvoltage(VCEsat)

2MaximumCollectorCurrent

3Thermallimit(Maxjunctiontemperature)

ll·fe.augmented

WhyusingSCRforHVdischarge?

Figure7.Nonrepetitivesurgepeakon-statecurrent

2

4000A

1

3

SCRhasaspecificationforNonrepetitiveCurrent

4000AforPeakCurrentof0.1ms2000AforPeakCurrentof1ms600AforPeakCurrentof10ms

ll·fe.augmented

BMSHVCapacitorDischarge

dedicatedSCRProducts

BatteryVoltage

DischargeEnergy

DischargeResistance

SCRPN#

BreakdownVoltage

PeakCurrent

CurrentrisedI/dt

Package

400V

300Joules

>0.2Ohms

>800V

<2000A

<450A/μs

D2PAK

TN4035HA-8

800V

1100Joules

>0.2Ohms

>1200V

<4000A

<450A/μs

TO247

TN13050HA-12

Pre-productionrelease

ESreleaseApr‘23

DischargePowerResistors

G

1100J0.6Ω

1000J0.2Ω

90J3Ω

ll·fe.augmented

A

K

THYRISTORHighCurrentclipassemblyD2PAK

TO-247

STDES-DIS001EvaluationBoard

400VBatteryTN4035HA-8

MidPoint

Discharge

GND

GND

LSSCR

IsolatedSupply

PowerResistor+12VHSSCR

Boostrapdiode

MidPointMCUControlPowerResistor

LS/GND/HS

control

ll·fE.augmented

CAPACITOR

3mF

Diagnostic

400V

400V400V

POWERRESISTOR

0.2Ω

1000Joules

LSclose

HSclose

LSclose

HSclose

Switchingfrom0Vto400V

0V0V

0V

ll·fE.augmented

CapacitivedischargeDiagnostic

500V,2.25mF,0.3Ohms

CapVoltage

MidPointHIGH

MidPointLOW

HSControl

LSControl

ll·fe.augmented

ll·fE.augmented

CAPACITOR

3mF

400V

POWERRESISTOR

0.2Ω

1000Joules

Discharge

0V

DischargeI

400V

DischargeCurrent

50V

990JoulesCapacitiveDischarge

850V,2.75mF,0.2Ohms

3750APeak

850V

1.5ms

50V

290A/μs

SCRtrigger

ll·fe.augmented

Pre-chargeofEVHigh

VoltagePowerBus

DFDToursApril2023

ll·fE.auente

16

ll·fe.augmented

Pre-chargeofEVHighVoltagePowerBus

1

Whydoweneedtopre-chargeHVBus?

2

Howtoimplementpre-chargewithThyristor?

3

Benchmarkingpre-chargeSwitch

4

Whatarethebenefitsof

THYRISTORpre-charge?

5

6

7

8

RecommendedSCRschematiccontrolforprecharge

HowtodetectHVBusdefault?

WebinarTakeAway

THYRISTORProductrange

ActivePre-chargewithTHYRISTOR

Apre-chargecircuitisusedtopreventstressanddamagetotheelectricsystembyimplementingaresistorandaswitchtolimitin-rushcurrent

Pre-chargeRelayareusuallyElectro-mechanicalcontactorusedinBatteryManagementSystem(BMS)andPowerdistributionUnit(PDU)

SCRcanreplacetraditionalpre-chargedRelayforamorereliable,smaller,andmoreresponsiveSolidStatesolutioncomparedto

mechanicalcontactswhichcanwearoutovertime.

17

ie.7ugrnsnieci

LimitIn-rushCurrentwithTHYRISTOR

18

ll·fe.augmented

PDUfunctionalitydescription

Pre-chargemode

?SCR1&RELAY2are

switchedONtochargeinputcapacitancethroughthepre-chargeresistance

?RELAY1isturnedONafterprecharge

Steadystatemode

?BothrelaysareswitchedONtotakeoverthecurrentconduction

?SCRswitchedOFFautomaticallysincethecurrentbecomeslowerthantheholdingcurrentIH

Dischargemode

?RelaysasswitchedOFFtodisconnecttheBattery

?SCR3isswitchedON,aftertherelaysareOPEN,todischargetheCapacitancethroughthe

powerresistance

Solidstateswitchesbenefits

Mechanicalrelays

?Slowswitchingspeed

?LargesizeoccupationonthePCB

?Highpowerconsumption

?Limitedlifespanduetothedegradationofthemechanicalcontacts

?EMIandnoisegeneratedduetomechanicalcontactbouncing

?Firehazardduetoarcingbetweencontacts

?MetalcontactsaresubjecttoWelding

Solidstateswitches

?Fastswitchingtime

?Highpowerdensityhandlinginmorecompactpackages

?Smallerandthinnerformfactor

?Higherreliabilityandincreaseofthelifespanbyreplacingmechanicalcontact

?Lowerpowerconsumption

?Safersolutionwithoutcontactarcing

ll·fe.augmented

Pre-chargeresistorsimpact

onPre-chargeduration1/2

2mΩ

850V

2mΩ

3mF

Pre-chargedesignexample

?Thepre-chargeresistorvaluehasakeyroleatdefiningthepre-chargedurationtime.

?Thehighertheresistance,theslowerthepre-charge.

?TheLowertheresistance,theHigherthecurrent.

ll·fe.augmented

Pre-chargeresistorsimpact

onPre-chargeduration2/2

2mΩ

850V

2mΩ

3mF

Pre-chargedesignexample

?Pre-chargecurrentisgoingthroughtheSCR(Pinkbars)

?SCRmustbeselectedaccordingtothepre-chargeresistance

?Afterpre-charge,theSCRwillautomaticallyturnOFFoncetheRELAY1isON

ll·fe.augmented

Pre-chargeresistor’simpact

onpeakcurrent

2m?

850V

2m?

3mF

Pre-chargedesignexample

?Thankstoitshighcurrentconductioncapability,SCRscanconducthighcurrentduringsmalltimeduration

?WhenPre-chargeresistorvalueisbelow1?,therelaycanbeturnedONwhentheSCRhasreachedtheturn-offcurrent

?SCRsenableusingsmallerpre-chargeresistors

ll·fe.augmented

Pre-chargeSCRscontrolsuggestions

DistributionUnit

RELAY1preventsleakagecurrentinDisconnectMode.

SW1isusedtodetectSHORTcircuitonHVDCBus.

CapacitorischargingthruSW1thatisactivatedbyMCU.

RELAY1

WhentheHVDCBusisnotshorted,SCR2canbelatchedONtoenablePre-chargesafely.

AfterPre-charge,RELAY2willbeturnedONandSCR2willunlatchasallcurrentflowthrutherelay.

Mode

RELAY1

SW1

SCR2

RELAY2

SCR3

Disconnect

OFF

OFF

OFF

OFF

OFF

SHORTdetection

ON

ON

OFF

OFF

OFF

Pre-charge

ON

OFF

ON

OFF

OFF

SteadyState

ON

OFF

OFF

ON

OFF

FastDischarge

OFF

OFF

OFF

OFF

ON

Power

SCR3

SCR2

SW1

D2PAKTO-247

ll·fe.augmented

ll·fE.augmented

ShortCircuitdetectionbeforepre-charge

SW1

Short-circuitDetection

SCR2Pulse

SteadyState

Relay2ON

Pre-charge

24

TAKEAWAY

G

A

K

ActiveDischargeandPre-charge

ofEVHighVoltagePowerBus

400VBATTERY

SCRPN#

BreakdownVoltage

PeakCurrent

CurrentrisedI/dt

Package

Pre-chargeR>0.2Ohms

TN4035HA-8*

>800V

<2000A

<450A/μs

D2PAK

DischargeR>0.2Ohms

TN4035HA-8*

>800V

<2000A

<450A/μs

D2PAK

*Productionpre-release

800VBATTERY

SCRPN#

BreakdownVoltage

PeakCurrent

CurrentrisedI/dt

Package

Pre-chargeR>0.2Ohms

TN13050HA-12*

>1200V

<4000A

<450A/μs

TO247

DischargeR>0.2Ohms

TN13050HA-12*

>1200V

<4000A

<450A/μs

TO247

*Engineeringsamples

ll·fe.augmented

D2PAK

TO-247

ST’sReferenceDesign

STDES-DIS001Colaterals

BoardSchematic

BoardLayout

KEYFEATURES

?ActiveDischargeSCRfor400Vbattery.

?ReferencedesignforDIAGNOSTIC&DISCH