Aluminum Electrolytic Capacitors for Industrial Applications · 2020-07-30 · TDK Aluminum...

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TDK Electronics AG

Aluminum & Film Capacitors Business Group • CAP ALU PD

Munich, Germany

July, 2020

IEEE PSMA Capacitor Comittee Industry Sessions 2020

Aluminum Electrolytic Capacitors for Industrial Applications

TDK Aluminum Electrolytic Capacitors for industrial applications

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TDK Electronics AG 2020

CAP ALU PD 07/20 2

Sebastian SchöllProduct DesignAluminum Electrolytic Capacitors

• 10 years experience in development and design-in of aluminum

electrolytic capacitors

• Responsible for product design of aluminum electrolytic capacitors

for industrial applications

Background:

+49 89 54020 2432

[email protected]

www.tdk.com

mailto:[email protected]

http://www.tdk.com/


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CAP ALU PD 07/20 3

Agenda

• Introduction TDK Aluminum Electrolytic capacitors

• Portfolio and target applications

• Outlook and new developments

• Simulation support


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CAP ALU PD 07/20 4

Introduction TDK Aluminum Electrolytic capacitors

Geographic Footprint: TDK CAP ALU

Iceland

Akureyri

Brazil

Gravataí

Hungary

Szombathely

Italy

Milan

China

Xiamen

Aluminum Electrolytic Capacitors

TDK Foil Italy/ Iceland (production of aluminum foil for

Electrolytic Capacitors)

Akureyri

Milan

Szombathely

Gravataí

Xiamen

TDK Foil

• Foil etching (IT)

• Foil forming (IS)

• Industrial (Motherfactory)

• Automotive (Europe)

• Automotive (Motherfactory)

• Industrial (local)

• Industrial

TDK benefit

Three capacitor factories on three

continents and key materials from

inhouse production


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CAP ALU PD 07/20 5

Agenda






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CAP ALU PD 07/20 6

Product Spectrum and Application - Industrial

5,60

Screw terminals 4-pin Snap-in/Solder pins

Applications:

Drives

Solar Inverter

SMPS

UPS

Automotive

Snap-in

Applications:

Drives

Solar Inverter

UPS

SMPS

Applications:

Drives

Wind energy generator

UPS

Traction

SMPS

Capacitors for pulse

applications

Applications:

Flashlight

Medical applications

Welding applications


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CAP ALU PD 07/20 7

HVAC Systems

-Drive in Precision air-con

➔DC-link: ST & SI

-Drive in Heat exchanger

➔DC-link: High Temp SI

AC/DC SMPS

-Servers

➔DC-link: Compact SI

UPS Systems

-AC UPS

-DC UPS

➔DC-link:

ST & SI in AC UPS

SI in DC UPS

AC/DC SMPS

-Switches & Routers

➔DC-link: Compact SI Trend to

High operating

temperatures >105°C

Compactness

capacitance / volume

Datacenters & 5GExtraordinary requirements for electrolytic capacitors


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CAP ALU PD 07/20 8

Motor management

Power steering

Transmission control

Wiper control

Fan control

On-board charger

Start-stopBoost Start Generator (BSG)

DC/DC converter (48 V boardnet)

Automotive“Industrial” components move to automotive

Trend to

Large and complex

mission profiles

Alternative cooling

methods


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CAP ALU PD 07/20 9

Servo DrivesRapid Charge/Discharge – Typical requirements for robotics

t

U

→ No standard specification is existing

→ Behavior is strongly depending on the actual waveform

→ Available for industrial Snap-In 105°C B43541, B43544, B43545 and B43547

Snap-in Screw terminal

∆U = 150V ∆U = 150V

f = 6Hz f = 3Hz

50 mio cycles 20 mio cycles

Typcial applications

- Pick and place

- Industrial robots

- Automatic production lines

- …

Demand

Motor Start → Discharge

Motor Stop → Charge

→ Frequent Charge / Discharge Cycles


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CAP ALU PD 07/20 10

Tomorrow…

Hybrid DC-links between FILM and ALU to exploit the benefits of different technologies in one system

and the day after

0

10

20

30

40

50

60

0

100

200

300

400

500

600

700

800

900

1000

0,1 1 10 100 1000

Inp

ut

Spe

ctru

m (

Arm

s)

Cu

rre

nt

(% r

esp

ect

to

inp

ut)

Frequency (kHz)

DC-Link Current Distribution

Film Capacitors Bank

Electrolytic Capacitors Bank

Film + Electrolitics Capacitors

Input Spectrum

Resonance AreaElectrolytic Area Film Area


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CAP ALU PD 07/20 11

Customized Design

5,60

Design to Cost solution

e.g. 430V / 8850µF

➔ Standard portfolio vs. customization

➔ Toolbox for customized designs & possibilitiy for customization

Design focus

● Ultra compact

● High ripple current

● Long useful life

● etc.

➔ Specific capacitor series available

Voltage

● ....

● 400V

● 450V

● 500V

● …

➔ Customization in 10V steps

Capacitance (µF)

● 100, 120, 150, 180, 220, 270, 330, 390, 470, 560, 680, 820, 1000, 1200, 1500, 1800, …

➔ Can be adjusted individually

Dimensions/Features

● Dimension customization

on request

● Bottom cooling / thermal

pads

● Copper inserts for highest

ripple currents

● Insulation materials PVC,

PET, PO (sleeves), PP,

ABS (cups)

Design in tip:

Example: Compared to a standard

450V 10.000µF capacitor, a 430V

8.850µF solution can be -20% more

cost effective

Design in tip:

The data book only contains select

material combinations. Our team will

gladly assist you in a tailored design

to fit your needs!


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CAP ALU PD 07/20 12

Agenda






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CAP ALU PD 07/20 13

Product News: Industrial products

5,60

B43647450 V

+105 °C/2000 h

B43707/727400/450 V

+85 °C/12000 h

B43743/763350 … 450 V

+105 °C/6000 h

compactness

performance

Snap-in Screw terminal

New in

DB2019Existing

Legend

B43548400 /450 V

+105 °C /3000 h

500 V

B43261400 /450 V

+125 °C /2000 h125°C

released

High ripple

current

compact compact

B43705/725350 … 450 V

+85 °C/12000 h

High ripple

current


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CAP ALU PD 07/20 14

Compact Snap-InProgress

Compactness

level2013 2014 2015 2016 2017 2018 2019 2020 2021

130%

120%

110%

100%B43640

200 … 450 V

105 °C/2000 h

B43641400 … 450 V

105 °C/2000 h

TDK NewTDK Existing TDK Potential

B43647450 V

105 °C/2000 h

B43xxx450 V

105 °C/2000 h

Design in tip:In order to utilize the full

potential of the state-of-the-art

Alu technology for new projects,

it’s beneficial to refer to the

latest TDK products.

Our team will gladly assist you in

the selection of the right product

to fit your needs!


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CAP ALU PD 07/20 15

High ripple current Snap-InProgress

Ripple current

level2011 … 2014 2015 2016 2017 2018 2019 2020 2021

160%

140%

120%

100%

B43544 upgrade400 … 450 V

105 °C/3000 h

TDK NewTDK Existing TDK Potential

B43548400 … 450 V

105 °C/3000 h

B43xxx400V … 450 V

105 °C/3000 h

B43543200 … 450 V

105 °C/3000 h

Design in tip:In order to utilize the full

potential of the state-of-the-art

Alu technology for new projects,

it’s beneficial to refer to the

latest TDK products.

Our team will gladly assist you in

the selection of the right product

to fit your needs!


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CAP ALU PD 07/20 16

High ripple current Snap-InNext step

IAC @ 50Hz 2019 2020

145%

130%

115%

100%

B43548400 … 450 V

105 °C/3000 h

B43xxx400V … 450 V

105 °C/3000 h

B43548400 … 450 V

105 °C/3000 h

Base cooling (Tc=70°C)

Natural convection (Ta=70°C)

Base cooling (Tc=70°C)

Features:

- Low ESR

- Low thermal resistance between base and winding

- Reinforced aluminum can with long-term rigidity

Reduced overall length tolerance (±0.2 mm) for effective heat sink mounting of capacitor banks

Suited for use of thin thermal pads.

Heatsink


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CAP ALU PD 07/20 17

Useful life (@ 50°C,

VR, 2m/s, 80% Imax,ref)2015 2017 2019

220%

180%

140%

100%

High ripple current Screw-terminal Significantly increased useful life at typical operating conditions

B43706400 … 500 V

85 °C/12000 h

B43705200 … 450 V

85 °C/12000 h

Ripple current

level 2015 2017 2019

130%

120%

110%

100%

B43705200 … 450 V

85 °C/12000 h

B43706400 … 500 V

85 °C/12000 h

Design in tip:

We recommend to consider the

operating conditions in the

design in process as soon as

possible in order to utilize the full

technical potential of the Alu

technology.


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CAP ALU PD 07/20 18

High ripple current Screw-terminalNext step

High ripple current

Increase the max. terminal current limit over 100A

Mechanical strength → Higher tightening torque (4Nm → 8-12Nm)

Material and geometry → Long lasting low contact resistance

Surface roughness → Highest possible contact surface

Co-planarity → Highest possible contact surface

Surface corrosion (e.g. Ni plating) → Long lasting low contact resistanceDesign option for all

screw terminal series


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CAP ALU PD 07/20 19

Agenda






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CAP ALU PD 07/20 20

Simulation supportTDK toolbox

→ Combination of test results and simulation → Optimized design-in support

→ All individual building blocks can be provided to customers for use in internal simulation environment

Electrical characteristics Finite Elements / CFD

¬ Material based simulation of

electrical characteristics

¬ Power loss calculation at actual

operating points

¬ FEM models for thermal simulations

¬ Material based simulation of thermal

networks

Lifetime evaluation

Life 420 V END

11000

2

3

5

10

20

30

50

70

90

10000 100000

[%]

¬ Useful life calculation tools for

complex operating conditions

¬ Online availability for easy use


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CAP ALU PD 07/20 21

AlCap: Useful Life Calculation Tool

1. User must specify

capacitor type and

load profile

2. Calculation results

of operating useful

life and relevant

thermal parameters

are displayed

3. Results can be

printed/ saved as

pdf-files

Link: https://www.tdk-electronics.tdk.com/en/180482/design-support/design-tools/alcap-useful-life-calculation-tool

Design in tip:

The AlCap tool is a public web-

based tool, that allows to

consider the operating

conditions in the design in

process of all industrial databook

products.

➔ AlCap = Web-Based Application for Useful Life Calculation of all high-voltage ST and SI Series (Data Book Series)

https://www.tdk-electronics.tdk.com/en/180482/design-support/design-tools/alcap-useful-life-calculation-tool

https://www.tdk-electronics.tdk.com/en/180482/design-support/design-tools/alcap-useful-life-calculation-tool

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Aluminum Electrolytic Capacitors for Industrial Applications · 2020-07-30 · TDK Aluminum...

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