magnet-technologie advanced softmagnetic … · esp variable variable speed drive speed drive...
TRANSCRIPT
© MAGNETEC GmbH, Langenselbold www.magnetec.de 05/2002 Dr. Fe 1/27
MAGNET-TECHNOLOGIEMAGNETEC
Advanced Softmagnetic Materials forAdvanced Softmagnetic Materials for EMIEMI FiltersFilters inin future Automotive Powernetfuture Automotive Powernet SystemsSystems
Advanced Softmagnetic Materials for Advanced Softmagnetic Materials for EMI EMI FiltersFilters in in future Automotive Powernetfuture Automotive Powernet SystemsSystems
21st Forum Vehicle Electrical Systems ArchitectureJune 27, 2002
Dr. Martin Ferch, MAGNETEC GmbH
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MAGNET-TECHNOLOGIEMAGNETEC
Advanced Softmagnetic Materials forAdvanced Softmagnetic Materials for EMIEMI FiltersFilters inin future Automotive Powernetfuture Automotive Powernet SystemsSystems
content of presentation
trends from MAGNETEC‘s point of viewEMC basics
material comparison: NANOPERM® vs. Ferriteproduction process of nanocrystalline cores
EMI filters and current compensated chokes
introduction of MAGNETEC GmbH
MAGNETEC GmbHDipl. Phys. Dr. Martin Ferch Managing DirectorIndustriestr. 7D-63505 Langenselbold
MAGNETEC GmbHDipl. Phys. Dr. Martin Ferch Managing DirectorIndustriestr. 7D-63505 Langenselbold
Tel. +49 6184 9202 27Fax +49 6184 9202 20
www.magnetec.de
Tel. +49 6184 9202 27Fax +49 6184 9202 20
www.magnetec.de
© MAGNETEC GmbH, Langenselbold www.magnetec.de 05/2002 Dr. Fe 3/27
MAGNET-TECHNOLOGIEMAGNETEC
Advanced Softmagnetic Materials forAdvanced Softmagnetic Materials for EMIEMI FiltersFilters inin future Automotive Powernetfuture Automotive Powernet SystemsSystems
introduction of MAGNETEC
MAGNETEC GmbH was founded 1984 as a privatecompany in Langenselbold near Frankfurt
production facilities in Hungary since 1989
specialized in development and production of softmagnetic tape wound cores
~ 280 employees, ISO 9001 certified
turnover 2001: 12 Mio € mainly in Europesuppling ABB, Siemens, Schneider Group etc. since many years with ~ 1 Mio products/month for earth-leakage circuit breakers and EMI filters
NANOPERM® cores were introduced 1999
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MAGNET-TECHNOLOGIEMAGNETEC
Advanced Softmagnetic Materials forAdvanced Softmagnetic Materials for EMIEMI FiltersFilters inin future Automotive Powernetfuture Automotive Powernet SystemsSystems
New PWM-systems with IGBT technology (e.g. inverter drives) in tomorrow‘s cars will increase radio-frequency-noise levels at the on-board-powernet
New PWM-systems with IGBT technology (e.g. inverter drives) in tomorrow‘s cars will increase radio-frequency-noise levels at the on-board-powernet
DC/DC converters (e.g. in 42/14V- systems)integrated starter/alternator (ISA)electrical brakeselectrical steering (EPAS)electrical air conditioning systems engine fan control high intensity discharge lamps (HID) .....
In parallel, other new and highly sensitive systems, like advanced motor management and security systems (multiple Airbags, ABS, ESP...) require an
even ‚cleaner‘ powernet in order to exclude malfunctions !
In parallel, other new and highly sensitive systems, like advanced motor management and security systems (multiple Airbags, ABS, ESP...) require an
even ‚cleaner‘ powernet in order to exclude malfunctions !
trends from MAGNETEC‘s point of view
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MAGNET-TECHNOLOGIEMAGNETEC
Advanced Softmagnetic Materials forAdvanced Softmagnetic Materials for EMIEMI FiltersFilters inin future Automotive Powernetfuture Automotive Powernet SystemsSystems
* Optimized solutions can be found on the basis of new materials – critical are in particular magnetic components like chokes and coils.
* Optimized solutions can be found on the basis of new materials – critical are in particular magnetic components like chokes and coils.
operational temperature up to 180°C and higherincreased functionality at smaller build volumeextended shock resisitivity ...
In this scenario, EMC is essential for a reliable and long term functionality of the whole vehicle system. (EMC = electromagnetic compatibility)
In this scenario, EMC is essential for a reliable and long term functionality of the whole vehicle system. (EMC = electromagnetic compatibility)
As a consequence, the requirements on EMI filtering will become significantly more stringent. State-of-the-art filter components may not be suitable, due to extended environmental boundary conditions like:
As a consequence, the requirements on EMI filtering will become significantly more stringent. State-of-the-art filter components may not be suitable, due to extended environmental boundary conditions like:
trends from MAGNETEC‘s point of view
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MAGNET-TECHNOLOGIEMAGNETEC
Advanced Softmagnetic Materials forAdvanced Softmagnetic Materials for EMIEMI FiltersFilters inin future Automotive Powernetfuture Automotive Powernet SystemsSystems
EMC basics: inverter drive as rf-noise source
e.g. asyn-chronous motor of ESP
variable speed drive (inverter) = noise sourcevariable speed drive (inverter) = noise source
~~~rectifier dc-link
control circuit
PWM inverter
DC DC~~e.g.
ISA
0
10
20
30
40
50
60
70
100 1000 10000 100000frequency [kHz]
Un
ois
e [
dB
µV
]
0
10
20
30
40
50
60
70
100 1000 10000 100000frequency [kHz]
Un
ois
e [
dB
µV
]
rf
variable voltage & frequency
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MAGNET-TECHNOLOGIEMAGNETEC
Advanced Softmagnetic Materials forAdvanced Softmagnetic Materials for EMIEMI FiltersFilters inin future Automotive Powernetfuture Automotive Powernet SystemsSystems
typical voltage andharmonics in a variable speed drive (inverter) –used in future Powernet systems. Thoseunwanted rf-signals are distributed over all connected wiring systems
EMC basics: sources of RF noise emissions
fundamental wave 4 kHz
0 20 40 60 80 100 kHz [f]0 20 40 60 80 100 kHz [f]
t = 50µs/unitt = 50µs/unit
T = 250µsT = 250µs
harmonics
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MAGNET-TECHNOLOGIEMAGNETEC
Advanced Softmagnetic Materials forAdvanced Softmagnetic Materials for EMIEMI FiltersFilters inin future Automotive Powernetfuture Automotive Powernet SystemsSystems
0
10
20
30
40
50
60
70
80
90
100
100 1000 10000 100000frequency [kHz]
Un
ois
e [
dBµV
]
EMC basics: typical noise spectra of inverter and converter
a) inverter drive, continuous spectrum, unfiltereda) inverter drive, continuous spectrum, unfiltered
conducted common mode noise in 50Ω-System conducted common mode noise in 50Ω-System
b) DC/DC converter, discrete spectrum of harmonics, with filterb) DC/DC converter, discrete spectrum of harmonics, with filter
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MAGNET-TECHNOLOGIEMAGNETEC
Advanced Softmagnetic Materials forAdvanced Softmagnetic Materials for EMIEMI FiltersFilters inin future Automotive Powernetfuture Automotive Powernet SystemsSystems
rf-sourceemissionradiation
rf-drainimmunity
radiated noise distribution
radiation
scenario: propagation of rf-noisescenario: propagation of rf-noise
conducted noise distribution
noise current noise voltage
Is
Us
EMC basics
capacitive andinductive coupling
E-fieldH-field
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MAGNET-TECHNOLOGIEMAGNETEC
Advanced Softmagnetic Materials forAdvanced Softmagnetic Materials for EMIEMI FiltersFilters inin future Automotive Powernetfuture Automotive Powernet SystemsSystems
EMC basics: ways of distribution of RF noise
typical distribution of emitted energy as a function of frequencytypical distribution of emitted energy as a function of frequency
MW SW FMLW
~am
ount
%100
50
01 kHz 100 1 MHz 1GHz10 10010
frequency f
conducted emission⇒ filtering
radiated emission⇒ shielding
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MAGNET-TECHNOLOGIEMAGNETEC
Advanced Softmagnetic Materials forAdvanced Softmagnetic Materials for EMIEMI FiltersFilters inin future Automotive Powernetfuture Automotive Powernet SystemsSystems
mains filter for conducted noise suppression
240Vmains
load
components of EMI filterscomponents of EMI filters
Cxn X-capacitor
Cyn Y-capacitor
L current compensated choke
R discharge resistor
Cxn X-capacitor
Cyn Y-capacitor
L current compensated choke
R discharge resistor
filterL1
N
PE
Cy2
R
Cx2
Cy2
Cx1
L
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MAGNET-TECHNOLOGIEMAGNETEC
Advanced Softmagnetic Materials forAdvanced Softmagnetic Materials for EMIEMI FiltersFilters inin future Automotive Powernetfuture Automotive Powernet SystemsSystems
the load current is not affected by a current compensated choke, but the rf-common mode noise is
the load current is not affected by a current compensated choke, but the rf-common mode noise is
working principle of common mode chokes
load current
RF currentHload = 0
Lload= 0
HRF ≠ 0LRF= Lnom
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MAGNET-TECHNOLOGIEMAGNETEC
Advanced Softmagnetic Materials forAdvanced Softmagnetic Materials for EMIEMI FiltersFilters inin future Automotive Powernetfuture Automotive Powernet SystemsSystems
main requirementmain requirement on an EMC on an EMC filter chokefilter choke::
choice of softmagnetic material
number of turns iron cross section(size of core)permeability !
Z(f) = ωL(f) = 2πf L(f)
L(f) = AL n2 with AL = µ0 µr(f) Afe/lf
⇒ high impedance Z !
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MAGNET-TECHNOLOGIEMAGNETEC
Advanced Softmagnetic Materials forAdvanced Softmagnetic Materials for EMIEMI FiltersFilters inin future Automotive Powernetfuture Automotive Powernet SystemsSystems
comparison of materials: NANOPERMNANOPERM® vs. Ferritevs. Ferrite
higher permeability - up to a factor of 10 (!)
alloy permeabilityµ‘r (10 / 100kHz)
saturation inductionBs [T] (25 / 100°C)
Curie-temp.Tc [°C]
working temp.Tmax [°C]
Ferrite 3E7 15.000 / 12.000 0,38 / 0,21 >130 95Ferrite T38 10.000 / 10.000 0,38 / 0,23 >130 95
NANOPERM® 100.000 / 20.00080.000 / 28.000 1,2 / 1,18 600 up to18030.000 / 20.000
higher saturation induction factor 3extended working temperature - up to 180°C
⇒ advanced, smaller, lighter and cooler components ⇐⇒ advanced, smaller, lighter and cooler components ⇐
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permeability as a function of temperaturepermeability as a function of temperature
0
10.000
20.000
30.000
40.000
50.000
-30 20 70 120 170T [°C]
perm
eabi
liy @
10k
Hz/
3mA
/cm
180
NANOPERM®
Ferrite
comparison of materials: NANOPERMNANOPERM® vs. Ferritevs. Ferrite
max. forFerrite:
about 120°C
max. forFerrite:
about 120°C
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MAGNET-TECHNOLOGIEMAGNETEC
Advanced Softmagnetic Materials forAdvanced Softmagnetic Materials for EMIEMI FiltersFilters inin future Automotive Powernetfuture Automotive Powernet SystemsSystems
saturation flux density as a function of temperature Tsaturation flux density as a function of temperature T
0
0,2
0,4
0,6
0,8
1
1,2
1,4
0 100 200 300 400T [°C]
satu
rati
on in
du
ctio
n B
sat
[T]
NANOPERM®
FerriteN67
T38
comparison of materials: NANOPERMNANOPERM® vs. Ferritevs. Ferrite
max. forFerrite:
about 120°C
max. forFerrite:
about 120°C
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MAGNET-TECHNOLOGIEMAGNETEC
Advanced Softmagnetic Materials forAdvanced Softmagnetic Materials for EMIEMI FiltersFilters inin future Automotive Powernetfuture Automotive Powernet SystemsSystems
permeability as a function of frequency fpermeability as a function of frequency f
comparison of materials: NANOPERMNANOPERM® vs. Ferritevs. Ferrite
1
10
100
1.000
10.000
100.000
1.000.000
0,01 0,1 1 10 100 1000f (kHz)
perm
eabi
lity
µ'NANOPERM®
Ferritebig advantageup to 100 kHzbig advantageup to 100 kHz
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MAGNET-TECHNOLOGIEMAGNETEC
Advanced Softmagnetic Materials forAdvanced Softmagnetic Materials for EMIEMI FiltersFilters inin future Automotive Powernetfuture Automotive Powernet SystemsSystems
typical impedance curve for different core geometriestypical impedance curve for different core geometries
20
10 100 f [kHz]
impe
danc
e Z
[k Ω
]
4
12
1.000 10.000 100.000
NANOPERM®
∅ = 40 mm
Ferrite∅ = 63 mm
comparison of materials: NANOPERMNANOPERM® vs. Ferritevs. Ferrite
volume reduction
> 50%
volume reduction
> 50%
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MAGNET-TECHNOLOGIEMAGNETEC
Advanced Softmagnetic Materials forAdvanced Softmagnetic Materials for EMIEMI FiltersFilters inin future Automotive Powernetfuture Automotive Powernet SystemsSystems
typical impedance curve at same core geometry Ø=30mm, 22 turnstypical impedance curve at same core geometry Ø=30mm, 22 turns
0
10
20
30
40
50
60
0,01 0,1 1,0 10,0 100,0frequency f (MHz)
atte
nuat
ion
leve
l [dB
]NANOPERM®
Ferrite
comparison of materials: NANOPERMNANOPERM® vs. Ferritevs. Ferrite
improved attenuation
below 500 kHz
improved attenuation
below 500 kHz
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Advanced Softmagnetic Materials forAdvanced Softmagnetic Materials for EMIEMI FiltersFilters inin future Automotive Powernetfuture Automotive Powernet SystemsSystems
NANOPERM®-chokeIN = 3 x 25A @ 60°C
LN = 3 x 1,6 mH @ 10kHzm = 120g
Ferrite-chokeIN = 3 x 25A @ 40°C
LN = 3 x 1,3 mH @ 10kHzm = 350g
comparison of materials: NANOPERMNANOPERM® vs. Ferritevs. Ferrite
73 mm
39 mm25 mm
59 mm
volume reduction 60% weight reduction 65 %
volume reduction 60% weight reduction 65 %
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Advanced Softmagnetic Materials forAdvanced Softmagnetic Materials for EMIEMI FiltersFilters inin future Automotive Powernetfuture Automotive Powernet SystemsSystems
principle of production process of rapidly quenched ribbons
melted alloyT= 1200°C
ribbon thickness: 17-24µm
amorphous ribbon v = 100km/h
© AMT
ceramic-nozzle
rotating Cu-wheel, T = 20°C
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Advanced Softmagnetic Materials forAdvanced Softmagnetic Materials for EMIEMI FiltersFilters inin future Automotive Powernetfuture Automotive Powernet SystemsSystems
slitting of ribbons with high precision knives
50-70 mm
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Advanced Softmagnetic Materials forAdvanced Softmagnetic Materials for EMIEMI FiltersFilters inin future Automotive Powernetfuture Automotive Powernet SystemsSystems
automatic winding process of tape wound cores
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furnace and batch of cores for magnetic-field treatment
60 cm
300 cm
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Advanced Softmagnetic Materials forAdvanced Softmagnetic Materials for EMIEMI FiltersFilters inin future Automotive Powernetfuture Automotive Powernet SystemsSystems
protective epoxy coating of tape wound cores
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available NANOPERM® products – cores and choke types
160 mm
tape wound cores from
10 ... 200 mm ∅
single phase EMC chokes up to I = 60A
three phase EMC chokes
up to I = 200A
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Advanced Softmagnetic Materials forAdvanced Softmagnetic Materials for EMIEMI FiltersFilters inin future Automotive Powernetfuture Automotive Powernet SystemsSystems
Conclusion / summary
EMI/EMC will definitely become much more important in future vehicle powernet architectures
there are new and advanced softmagnetic materials which are able to provide solutions
EMI/EMC will become essential for thefunctionality of future vehiclesFilter solutions based on state-of-the-art components may not work/not be optimal
these new materials are available from several sources and their prices will come down as their market penetration actually grows rapidly