Electrification of EV Automobiles and Trucks Shifts into High Gear
Evolution of Electronics in Automobiles
Acceleration of the EV Market
BloombergNEF extends predictions out even further. According to their EV forecast 2018, sales of EVs are predicted to increase from a record 1.1 million worldwide in 2017 to 11 million in 2025, and then surging to 30 million in 2030 as they become cheaper to make than internal combustion engine cars. China will lead this transition, with sales in the region accounting for almost 50% of the global EV market in 2025.
Key Technology Building Blocks for EV Success
Regardless of voltage level, all require some level of inversion from DC to AC voltage to drive the fields within the motors. Moreover, many of the challenges remain similar, such as how to integrate all the functions and associated subassemblies needed for current inversion into the smallest possible package with electrically efficient short path interconnects.
Conventional designs focused less on tightly integrating functionality, with most design approaches consisting of multiple discrete assemblies such as: Power DBCs, Capacitor Modules, Control Printed Circuit Boards (PCBs), and Multiple Bus Assemblies. These were connected by a variety of methods including: numerous wire-bonds, bolts, bus structures, harnesses, connectors, and solder-joints. The result was typically large, bulky and heavy power devices that exhibited high inductance and relatively low efficiency– all at a fairly high cost.
To support EV requirements, new-generation inverters need advanced interconnect and mechatronics solutions to maximize efficiency and optimize size and cost by tightly integrating all of the functionalities above into small-footprint inverters with compact pluggable sub-assemblies.
Battery Interconnect Systems
Flexible Solutions for Busbar Integration
Key features include:
- Compact size: 8.4 x 6.0 x 9.9mm
- Excellent ampacity-size ratio
- Accommodates large assembly tolerances: ±0.8 mating blade offset, twist or insertion depth
- Customizable and scalable for higher currents
- High temperature construction: 125°C
The technology areas described above: 1) power inverters, 2) battery interconnect systems, and 3) high-efficiency busbar interconnects, represent critical enabling solutions that vehicle makers can apply across a wide range of EV implementations.