POWER FORUM 2014 CONCEPT: Un Elettrolitico modulare da 700 a 1200 Volt e fino a 250ARMS per applicazione di potenza “Modular Electrolytic capacitor from 700 to 1200Volt up to 250Arms for power application” Gabriele Righi R&D/ Technical Marketing Manager Confidentiality & Disclaimer CONFIDENTIALITY • The recipient of the information contained in this presentation, in receiving it, agrees not to copy or disclose any of its contents to third parties without the written consent of Kendeil S.r.l., and to restrict the use of any of this information to those people within its organization or retained advisors who have been informed of its confidentiality. DISCLAIMER • • • The information contained in this Presentation is intended to be a fair and accurate representation of the Business, its historical performance and prospects, based on information available from internal management reports and analyses. However, this information is selective and is subject to updating, expansion, revision and amendment. It does not purport to contain all the information that Recipients may require. No obligation is accepted to provide Recipients with access to any additional information, or to update, expand, revise or amend the information, or to correct any inaccuracies which may become apparent. Recipients should conduct their own investigation and analysis of the Business and of the information contained in this Presentation and are advised to seek their own professional advice on the legal, financial, taxation and other consequences of acquiring the Business. None of Kendeil S.r.l., nor the directors, shareholders, managers, employees or agents of them, has verified any of the information contained herein, and no such party, entity or person makes any representation or warranty, express or implied, as to the accuracy, or completeness of the information contained in this presentation. This Memorandum includes certain statements, estimates and projections with respect to the anticipated future performance of the Business and as to the market for the Business’s products. Such statements, estimates and projections reflect various assumptions made by the owners and by the management of the Business concerning anticipated results, which assumptions may or may not prove to be correct. No representation is made as to the accuracy of such statements, estimates and projections. 2 1 Market requests around the world are…. Mechanical requests Electrical requests . Strong miniaturization with high capacitance value High working voltage High ripple current Transient by very high ripple current (boost cycle - high speed motor cycles) Long expectancy of life into application conditions ------------------------------------------------------------------------------------------------------------ Direct assembly with two/three levels IGBT power module (+ Vn, central point, - Vn) Easy mechanical assembling for modular machine. Low profile capacitor. -----------------------------------------------------------------------------------------------------------3 Concept’s target Electric target: - Miniaturization and high ripple current transient: 250Arms - High voltage: 700V - 1200V, low ESR design for high ripple current without de-rating of nominal temperature (85°C- 105°C) without de-rating of nominal life (12000H- 5000H) - Increase expectancy of life on typical working conditions versus actual design done by electrolytic capacitors - Central point of voltage range for three levels IGBT connection. 4 2 Concept’s target Mechanic target: - Compact sizes by square and low profile layout. - Easy and modular installations on power machine - End connections designed for bus bar or directly connectable to IGBT module - Flexible design for customized solutions (different air flow value and direction, liquid cooling, etc..) - Strong internal design versus long term vibration stress. 5 Concept capacitor All targets have been reached by …. 6 3 Concept Capacitor. Electrical performances • K1M -40°C +85°C 12000H Electrical parameter Cap (uF) Vn Vr Vs ESR typ (20°C/100Hz) Ir rms (85°C,100Hz) 8200 6800 6000 5600 3700 2500 1700 700 800 840 900 1000 1100 1200 644 736 773 828 920 1012 1104 770 880 924 990 1050 1156 1260 10 11 12 12 32 60 64 68 65 61 60 52 41 39 mechanical dimensions without heat sink Ir rms I transient rms (25°C,10KHz) MAX 190 181 170 167 145 114 109 250 250 250 250 250 250 250 L (mm) D (mm) H (mm) 265 265 265 265 265 265 265 120 120 120 120 120 120 120 110 110 110 110 110 110 110 Vn = Nominal Voltage Vr = Rated Voltage Vs = Surge voltage Ir defined by natural air flow and heat sink 7 Concept Capacitor. Electrical performances • K2M -40°C +105°C 5000H Electrical parameter Cap (uF) Vn Vr Vs ESR typ (20°C/100Hz) 7200 6000 5600 4800 3000 700 800 840 900 1000 665 760 798 855 950 770 880 924 990 1100 11 12 12 14 33 mechanical dimensions without heat sink Ir rms Ir rms I transient rms (105°C,100Hz) (25°C,10KHz) MAX 33 30 29 29 24 194 177 171 171 141 250 250 250 250 250 L (mm) D (mm) H (mm) 265 265 265 265 265 120 120 120 120 120 110 110 110 110 110 Vn = Nominal Voltage Vr = Rated Voltage Vs = Surge voltage Ir defined by natural air flow and heat sink 8 4 Concept Capacitor. Electrical performances K1M 5600uF / 900V ESR MATRIX (mohm) Frequency (Hz) 20°C 50 14,0 100 11,4 200 9,2 300 8,5 500 7,9 1000 7,5 2000 7,4 5000 7,2 85°C 5,6 4,6 3,7 3,4 3,2 3,0 2,9 2,9 - Very low Equivalent Series Resistance especially for high voltage electrolytic capacitors - Very low and stable value versus switching frequency (> 1KHZ) 9 Assembling examples. • Capacitors can be mounted horizontally or vertically in order to minimize thermal resistance of heat sink and to adapt it to the best machine layout. AIR FLOW DIRECTION: Vertical and horizontal assembling in case of natural or forced air flow 10 5 Assembling examples. • Capacitors can be mounted horizontally and very close to IGBT heat sink in order to use same air flow direction Capacitor Module Capacitor Module IGBT Module To be avoid Horizontal assembling for forced air flow close. 11 Assembling examples. • Capacitor can be mounted horizontally and very close to IGBT heat sink using the same liquid cooling system. Capacitor Module IGBT Module Horizontal assembling for liquid cooling system 12 6 Comparison K1M 5600uF/900V versus cylindrical electrolytic capacitors like K01 5600uF/450V – K21 5600uF/450V series capacitance uF Voltage V # cap. Ir max Arms space dm3 References K1M 5600 900V 1 166 3,5 Same capacitance value by similat K01 K21 K01 K21 5600 5600 8400 7050 450V 450V 450V 450V 4 4 6 6 106 139 158 188 3,7 3,7 5,3 5,3 Similar ripple current Result -40% of max current - 20% of max current +150% of applied volume +150% of applied volume . It’s not possible to reach similar performance of K1M by assembling of cylindrical electrolytic capacitors 13 Comparison K1M 5600uF/900V versus cylindrical electrolytic capacitors Life expectancy versus possible application conditions for 5600uF/900V DC link capacitor. - 60°C Natural air flow 60 Arms 300Hz 800V • Expected life of K1M • Expected life by Snap in style = 71.000 Hours • Expected life by Screw style = 132.000 Hours = 81.000 Hours 14 7 Comparison K1M 5600uF/900V versus cylindrical electrolytic capacitors Life expectancy versus possible application conditions for 5600uF/900V DC link capacitor. - 60°C 2 m/sec 60 Arms 300Hz 800V • Expected life of K1M • Expected life by Snap in style = 91.000 Hours • Expected life by Screw style = 156.000 Hours = 107.000 Hours 15 K1M 5600uF/900V performances under 250 Arms • Thermal model K1M and hot spot temperature with applied 250Arms/10KHz, natural air flow, 20°C. 16 8 K1M 5600uF/900V performances under 250 Arms • Thermal model K1M and hot spot temperature with applied 250Arms/10KHz, 2m/sec air flow, 20°C. Due to air flow we have -20°C of hot spot and it means 4 times more of expected life under higher ripple current conditions 17 Comparison K1M-K2M versus cylindrical electrolytic capacitors • Low inductance connections for high switching frequencies. • Safety. Capacitor frame is close and very strong in compare to can of cylindrical capacitors, it’s designed in order to avoid free electrolyte outside the component in case of overvoltage or overpressure due to bad working conditions. • Safety. Capacitor frame is full insulated by voltage (10000Vac). • Using K1M-K2M should be easy to reach UL certification for final machines. 18 9 Comparison K1M 5600uF/900V versus power film capacitors Cylindrical can film solution like K31 550uF/900V • By similar volume and similar ripple current.. The max capacitance value is 1500uF versus 5600uF by K1M • In case of 5600uF the used volume is +400% • No central point is available for three level IGBT Box film solution: • Max capacitance value is 1200uF/900V by similar volume • Humidity problems by life reductions Brick film capacitor. • Brick 4700uF/1100V with 270Arms: +240% of dm 3 more than #2 K1M 2500uF/1100V. 19 Performances, goals and results. - Easy assembling for modular solutions direct connectable to IGBT Module - Easy customized solution by flexible drawing. --------------------------------------------------------------------------------------------------------------- High ripple current permitted like 250 Arms - Voltage range from 700V to 1200V without de-rating of life, temperature and ripple current. - More expected life in compare assembled electrolytic solution. - High Capacitance density and low humidity sensibility versus film solution --------------------------------------------------------------------------------- Studied performances versus mechanical vibrations - Safety point of view kept into consideration 20 10 Products corollaries by linked R&D projects. Kendeil’s catalogue 2015. K71 - very high miniaturization Example for screw type K01 compact K91 - low ESR design K21 - very low ESR desing K71 4700uF/450V by 63x105 – 15.8 Arms K21 4700uF/450V by 76x143 – 26.0 Arms K72 - very high miniaturization versus K02 compact K92 -low ESR desing K22 - very low ESR design K01 4700uF/450V by 76x143 – 15.0 Arms Example for snap in type K85 470uF/450V by 35x50 – 3.06 Arms K75 - very high miniaturization K75 470uF/450V by 30x40 – 1.83 Arms versus K05 compact K95 -low ESR desing K85 - very low ESR and long life as 8000H K05 470uF/450V by 35x50 – 1.80 Arms 21 THANK YOU FOR YOUR ATTENTION 22 11
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