Gallium nitride (GaN) offers significant benefits of increased efficiency and power density, and allows designers to meet far more challenging power supply specifications than they can with silicon MOSFETs. &nbsp;One reasonable concern about any new technology that offers game-changing benefits is robustness and reliability. To address any doubts that potential users may have, let’s discuss the robustness, reliability and quality of GaN.GaN, as a power conversion technology, does not have as long a pedigree as silicon. Even so, the bathtub curve as a representation of the failure rate of a device over time is certainly very well established and multiple companies have contributed to fleshing out the details as they pertain to the new GaN devices. It is a useful visualization tool for reliability engineering and deterioration modeling, and serves as a clear mechanism to discuss why failures occur and how to predict and prevent them.&nbsp;‘Bathtub' of course, refers to the shape of the curve. The x axis in Figure 1 is the log of time, and the y axis is the probability of failure. The green line – our bathtub curve - is the rate of failure of a typical product over time. In the early phase of a product's life, failures are mainly quality-related due to manufacturing defects. In the center zone, there are devices that were well manufactured, and that haven't yet worn out, but they failed anyway, typically because these parts have been overstressed. Then, after some time, parts wear out, so the failure mode is due to lifetime issues.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1732548346749-PI+Doug+Bailey+Fig+1+1.12+%281%29.jpg" style="width: 100%px;" class="fr-fic fr-dib">Figure 1<h3>Lifetime</h3>If we consider failures in the far distant future, the challenge is that users can’t wait for, say, 100,000 hours (11 years), or a century, one million hours, for a device to fail before the wear-out mechanisms can be investigated. To accelerate time for the purposes of IC testing, a test called High Temperature Operational Life (HTOL) is employed. This leverages the tendency of physical systems to change faster with temperature, under strong electric fields and in the presence of free ions (humidity and metal migration), to accelerate the effects of time and use on the devices under test. Surprisingly, a relatively few parts (48 for commercial and 77 for automotive) when tested with acceleration over 1000 hours provide the information that we need to determine the probability of failure in many years under normal conditions. The test is run on multiple batches of devices to expose any process dependency. Another test, called HALT (highly accelerated life test), applies a similar test under increased humidity but at a slightly lower temperature.&nbsp;These tests are standard procedure for analog integrated circuits. But because GaN is a new technology, users and manufacturers must make doubly sure that the GaN switch inside the IC is robust and will have a long life, and there are tests specifically designed for discrete transistors called HTRB (high temperature reverse bias) and HTGB (high temperature gate bias) which address this. HTRB and HTGB test the device for 1000 hours at elevated temperatures under a DC voltage stress to make sure there are no migration issues, or long term degradation mechanisms associated with high voltage operation at high temperature. Hot Carrier Tests (HCI) are also performed to find any places where electrons in the channel can get diverted into oxide layers and become trapped. Electro-migration testing makes sure that the metal conductors on the top of the die are appropriately sized for the current that they carry. And gate oxide integrity tests prove the strength of the gate. All these tests are performed on devices intended for industrial and commercial customers.&nbsp;Of course, GaN is also very suitable for the automotive market, which is even more demanding. So in addition to the usual tests just described, for automotive devices we run more tests, primarily H3TRB, which increases the humidity and temperature demands above the standard HTRB. Then we run a series of tests that are designed to switch the part on and off multiple times to prove that the devices are immune to the thermal shock of being switched on. These tests are called Power Temperature Cycling and Intermittent Op Life - the latter was originally a military test. As well as stressing the devices to a higher level, automotive tests are carried out on a larger sample size than for commercial and industrial parts.&nbsp;<h3>Manufacturing quality </h3>So much for the long term; we also need to address manufacturing quality problems that can cause parts to fail in early life. Power Integrations’ quality policy is to prevent any of these parts from entering the product stream. You might think that a robust final test of finished products would catch all of the mis-manufactured devices, and that is certainly an important part of it. However, in order to create an essentially perfect product stream, we work hard to screen out substandard material in prior manufacturing steps – using so-called “process monitors”. These monitor tests reduce the number of parts with latent defects that make it into final test and are critical for improving final product quality.&nbsp;Power Integrations regards epitaxially grown GaN (EPI) as the critical stage in GaN transistor design and production. Because of this, we make our own EPI – we don’t buy it, nor finished wafers, from a third party. Therefore we have complete control over the process, and we can check it continuously. This means that only the best wafers make it through to patterning. After a wafer has been patterned into transistors, we run stress tests to identify parts that are faulty or have a risk of a quality problem.To validate that our process monitors, our yield improvements and our final test regime yield a perfect product stream, a test called ELFR (Early Life Failure Rate) is used. ELFR is analogous to the High Temperature Op Life (HTOL) test. But instead of doing a small number of parts for a long time, we do a large number of parts for a relatively short time - 800 parts for 48 hours, across multiple IC lots to ensure that any process dependencies are exposed.&nbsp;<h3>Overstress</h3>We've spoken about reliability and wear out mechanisms and how to guarantee initial quality. But what happens in the middle section of our bathtub curve? These are parts that have been manufactured perfectly. They haven't worn out yet, yet they are dead anyway due to overstress.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1732548369476-PI+Doug+Bailey+Fig+2+11.19+%281%29.jpg" style="width: 100%px;" class="fr-fic fr-dib">Figure 2To ensure that our devices are robust under the temperature, voltage and humidity conditions that they will be exposed to during their operational life, we run more tests. These are:l&nbsp;MSL - moisture sensitivity level;l&nbsp;UHAST - also a moisture test, but under pressure;l TMCL - a temperature cycling test which tests for differential heating and cooling; and&nbsp;l HTSL - high temperature storage life which is the absolute high temperature test.&nbsp;One of the most important attributes of a power semiconductor is its ability to withstand voltage. Power Integrations specifies three types of GaN, with BVs (breakdown voltages) of 750 V, 900 V and 1250 V. However, even though we talk about BV for convenience, GaN transistors are not specified in the same way as a silicon device. There's a property of GaN called dynamic RDS(ON)&nbsp;which actually increases when high voltage is applied. It recovers later, but under the initial voltage, and for a short while afterwards, it is higher than the typical value.&nbsp;Power Integrations has chosen 5% as being the limit that we can accept as an increase in RDS(ON). This determines the datasheet ‘BV’ of our GaN devices. We choose the conservative values noted above for the datasheet specification, but actual breakdown does not occur until around 1400 V for the lower voltage families and 2200 V for the 1250 V product line – in all cases, a massive margin with respect to the datasheet BV limits. It’s unwise to design systems to use the devices above the datasheet BV, but this headroom is very useful insurance against infrequent line swells and surges, such as lightning strikes.<h2>Conclusion</h2>With this battery of tests (Figure 2) - process monitors for initial quality, voltage margin to allow for overstressing, wear-out mechanisms that ensure reliability, plus tests related to temperature and moisture sensitivity - whether you're making a smart phone adapter or an automobile, you can have confidence in PowiGaN™, Power Integrations’ GaN technology.

Gallium nitride (GaN) offers superior efficiency and power density, with reliability assessed using the "bathtub curve" to predict and prevent failures from defects, overstress, and aging.

Quality, Robustness and Reliability - Breaking Down the Bathtub

An interview with Adam White from Infineon on Powering the Next Generation of AI Data Centers.

There is No AI Without Power

<h2 dir="ltr" id="isPasted">Introduction</h2>In modern automotive engineering, Metal Oxide Semiconductor Field Effect Transistors (MOSFETs) are fundamental components that enhance the performance, efficiency, and safety of vehicle electronics. Serving as key components in power management systems, motor controls, safety mechanisms, and various other vehicle subsystems, the reliability and performance of MOSFETs significantly impact the efficiency, safety, and overall driving experience of both electric vehicles (EVs) and internal combustion engine (ICE) vehicles. Consequently, the quality of MOSFETs is a non-negotiable aspect.This article provides a detailed look at high-performance MOSFETs tailored for automotive applications, focusing on their essential functions, performance metrics, and rigorous quality standards. Additionally, it examines Nexperia's contributions to the evolution of the technology, highlighting real-world applications and discussing the trends currently shaping the industry.<h2 dir="ltr">Understanding Automotive MOSFETs</h2>MOSFETs are pivotal components in the architecture of modern automotive electronics. Their ability to efficiently switch and amplify power makes them a critical component across various systems within vehicles.<h3 dir="ltr">Function and Importance of MOSFETs in Automotive Systems</h3>MOSFETs are integral to the functionality of numerous automotive systems, serving as critical components in power management and signal processing across various applications. Their ability to handle high currents and voltages efficiently while switching and amplifying signals makes them a vital electronic component in modern vehicles. Here’s a closer look at some specific applications:<ul><li dir="ltr" style="font-weight: bold;">Powertrain and Vehicle Dynamics:<ul style="font-weight: initial;"><li dir="ltr">Advanced Driver Assistance Systems (ADAS) radar sensor module:&nbsp;MOSFETs regulate the power distribution to the radar components of ADAS, ensuring optimal performance by managing the precise control of high currents needed for the radar's operation.</li><li dir="ltr">Electronic Power Steering (EPS): MOSFETs modulate the power supplied to the electric motor that drives the steering mechanism, allowing for precise control and responsiveness, enhancing both the efficiency of steering operations and the overall safety and comfort for the driver.</li><li dir="ltr">Anti-locking braking systems/Electronic Stability Control (ABS/ESC): Critical in providing the rapid switching needed for effective electronic stability control and braking systems.</li></ul></li><li dir="ltr" style="font-weight: bold;">Vehicle Comfort and Convenience:<ul style="font-weight: initial;"><li dir="ltr">Adaptive Front LED lights and Interior LED lighting:&nbsp;MOSFETs drive the lighting systems, offering precision control that adapts to varying conditions and user settings.</li><li dir="ltr">Automatic Heating Ventilation and Air Conditioning (HVAC):&nbsp;Ensures efficient motor control for heating, ventilation, and air conditioning, enhancing passenger comfort.</li><li dir="ltr">Active Suspension System: MOSFETs facilitate the rapid adjustment of suspension settings to adapt to road conditions to improve ride quality and vehicle handling. This technology contributes to a smoother driving experience by dynamically managing the suspension's response to changes in terrain.</li></ul></li><li dir="ltr" style="font-weight: bold;">Safety Systems:<ul style="font-weight: initial;"><li dir="ltr">Airbag controller with Safing MOSFET:&nbsp;Controls the deployment of airbags in a crash situation, ensuring timely and reliable activation.</li><li dir="ltr">Seat Belt Pretensioners and Force Limiters: MOSFETs control the mechanisms that tighten seat belts instantly during a collision, reducing slack to protect occupants. They also regulate the force limiters to ensure that the belt tightens adequately without causing injury, enhancing passenger safety during severe impacts.</li></ul></li></ul><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1729694339156-image1.jpg" style="width: 100%px;" class="fr-fic fr-dib" alt="mosfet-applications-vehicle"><ul id="isPasted"><li dir="ltr" style="font-weight: bold;">Power Management in EVs/Hybrids:<ul style="font-weight: initial;"><li dir="ltr">High power, high-efficiency DC/DC converter and On-Board Charger (OBC): Essential for converting and managing power within the vehicle’s electrical system, crucial for electric and hybrid vehicles.</li><li dir="ltr">Zonal Control Units: MOSFETs facilitate intelligent power distribution controlled by software, optimizing the delivery of power to different zones of the vehicle. This not only enhances the efficiency of electrical systems but also supports advanced features such as customized lighting and climate control across different cabin areas.</li><li dir="ltr">Battery Management System (BMS):&nbsp;MOSFETs play a crucial role in managing systems that monitor and control battery packs, crucial for EV performance and safety. They also help in the balanced charging of battery cells, a process that is critical for maintaining the health and extending the lifetime of the battery. By ensuring each cell within the battery pack is charged correctly, MOSFETs prevent overcharging and help maintain the overall battery balance, thus safeguarding and maximizing battery life.</li></ul></li><li dir="ltr" style="font-weight: bold;">Applications in ICE vehicles:<ul style="font-weight: initial;"><li dir="ltr">Cooling Fan and Fluid Pump Controls:&nbsp;Manage the operation of cooling systems and fluid circulation, which are vital for maintaining the operational integrity of engine and battery systems.</li><li dir="ltr">Electronic Fuel Injection:&nbsp;Improves the efficiency and control of fuel delivery to the engine, optimizing performance and reducing emissions.</li></ul></li></ul>MOSFETs’ versatility enables them to support these (and many more) critical functions across various systems within the vehicle, highlighting their importance in the automotive industry.<h3 dir="ltr">Key Performance Metrics for MOSFETs</h3>The high performance, efficiency, and reliability of MOSFETs in automotive applications are essential for ensuring the smooth operation of vehicle electronics. These metrics include:<ul><li dir="ltr" style="font-weight: bold;">Electrical Efficiency:<ul style="font-weight: initial;"><li dir="ltr">Switching Efficiency:&nbsp;Effective switching speeds for automotive power MOSFETs typically range from tens to hundreds of nanoseconds, essential for fast response times in power-intensive applications. Small signal MOSFETs, which are also qualified for automotive use, can switch in just a few nanoseconds, providing even faster response for applications requiring high-speed signal processing.</li><li dir="ltr">On-state Resistance:&nbsp;Lower on-state resistance increases efficiency by reducing power losses. Typical values range from 10 mΩ to sub &lt;1mΩ, ideal for minimizing heat generation and energy wastage.</li><li dir="ltr">Power Limits:&nbsp;These are determined by the maximum voltage and current the MOSFET can handle—commonly between 5V to 100V and 10A to 2000A—suitable for a variety of automotive functions.</li></ul></li><li dir="ltr" style="font-weight: bold;">Thermal Performance:<ul style="font-weight: initial;"><li dir="ltr">Operating Temperature Range:&nbsp;Automotive MOSFETs must operate effectively within a range of -55°C to +150°C, with short-term tolerance of up to 175°C for high-heat environments such as engine compartments.</li><li dir="ltr">Thermal Resistance of Junction-Base Mounting: &nbsp;This parameter, ranging from 0.5K/W to 2K/W, indicates the capability of heat dissipation. Lower values are preferable, as they denote superior thermal management.</li></ul></li><li dir="ltr" style="font-weight: bold;">Durability and Longevity:<ul style="font-weight: initial;"><li dir="ltr">Thermal Cycling Resistance:&nbsp;MOSFETs are designed to withstand numerous thermal cycles without performance degradation, ensuring long-term reliability. Additionally, they must pass rigorous electrical bias stress tests, including high temperature gate bias, high temperature reverse bias, and humidity bias stress. These tests are critical for assessing the durability of MOSFETs under severe environmental conditions and electrical stresses, further ensuring their robustness and suitability for demanding automotive applications.</li></ul></li></ul>Suggested reading:&nbsp;<a href="https://www.wevolver.com/article/next-generation-mosfet-technology-meets-demand-for-strong-thermal-performance-in-automotive-applications" target="_blank">Next-generation MOSFET technology Meets Demand for Strong Thermal&nbsp;Performance in Automotive Applications.</a><h2 dir="ltr">Quality Standards and Certifications</h2>MOSFETs used in automotive applications are subject to specific industry standards that dictate their design, testing, and performance criteria. One of the most critical standards is the AEC-Q101, a stringent specification from the Automotive Electronics Council that covers stress tests for semiconductors in automotive applications. This standard ensures that MOSFETs can withstand extreme conditions such as high temperatures, vibrations, and varying electrical loads.Compliance with AEC-Q101 involves multiple tests, including thermal shock, moisture resistance, electrostatic discharge susceptibility, and life-cycle testing. These tests are designed to simulate the actual operating conditions that MOSFETs will face in a vehicle, ensuring that only the most robust components make it into automotive systems.&nbsp;Suggested reading: <a href="https://www.wevolver.com/article/semiconductor-resilience-with-innovations-in-testing-techniques-and-packaging" target="_blank">Semiconductor Resilience with Innovations in Testing Techniques and Packaging</a><h2 dir="ltr">Trends and Innovations</h2>The automotive industry is on the brink of a big technological transformation, with MOSFETs playing a crucial role in shaping the future of mobility. As the demand for EVs and autonomous driving systems increases, MOSFETs are evolving to meet the new challenges and performance requirements.New materials such as Silicon Carbide (SiC) and Gallium Nitride (GaN) are making their way into MOSFET design. These materials offer superior efficiency, higher breakdown voltage, higher temperature tolerance, and faster switching capabilities than traditional silicon MOSFETs, making them ideal for the high-power demands of EV powertrains and charging systems.Additionally, the integration of intelligent control features within vehicle subsystems is becoming more common. Smart power converters can provide real-time diagnostics and protection features, enhancing the overall safety, reliability and repairability of automotive electronics.Moreover, as vehicles become more connected and autonomous, the number of electronic components and systems is set to increase continuously, necessitating MOSFETs that can perform reliably in a more crowded and interconnected environment. The ongoing development in MOSFET technology also aims to reduce interference and improve communication between components, ensuring seamless operation.<h2 dir="ltr">Nexperia's High-Performance MOSFETs: Driving Excellence and Innovation in Automotive Electronics</h2>Nexperia distinguishes itself in the automotive electronics market with a strong focus on quality, performance, and innovation. As a semiconductor manufacturer, Nexperia is committed to developing MOSFET technology that meets the stringent requirements of modern automotive systems.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1729694884790-image3.png" style="width: 100%px;" class="fr-fic fr-dib" alt="lfpak-family">MOSFETs optimized for Automotive applications by Nexperia in an LFPAK package. Source: Nexperia<h3 dir="ltr">Innovative Product Range</h3>Nexperia’s automotive MOSFET product portfolio contains over 400 types of power MOSFETs, with specifications ranging from -18 &nbsp;to 500 A for drain currents and drain-source voltage ratings ranging from -60to 100 V. These are housed in robust copper-clip packages featuring cutting-edge technologies, such as flexible leads and wettable flanks for ease of Automatic Optical Inspection (AOI) and improved reliability. This diversity ensures solutions for every automotive electronic need, from simple lamp circuits to complex power requirements of vehicle electrification and hybrid battery systems.Suggested reading:&nbsp;<a href="https://www.wevolver.com/article/a-story-of-innovation-how-lfpak-revolutionized-an-industry" target="_blank">A story of innovation: How LFPAK revolutionized an industry.</a><h3 dir="ltr">Focused on Future Needs and Sustainability</h3>Nexperia is further advancing MOSFET technology with initiatives like the introduction of the <a href="https://www.nexperia.com/products/sic-mosfets" target="_blank">1200 V Silicon Carbide MOSFETs</a>, which enhance efficiency and reduce energy waste—crucial for extending the driving range of EVs. The company's efforts in scaling down MOSFET sizes allow for more compact system designs without compromising performance or reliability. These innovations support the automotive industry’s goals of reducing carbon footprints and advancing sustainable mobility solutions.<iframe width="640" height="360" src="https://www.youtube.com/embed/pD7b3YkhG6s?&amp;pp=ygUPbmV4cGVyaWEgbW9zZmV0&amp;wmode=opaque&amp;rel=0" frameborder="0" allowfullscreen="" class="fr-draggable">&nbsp;</iframe><h3 dir="ltr">Specialization for Reliability</h3>Tailoring MOSFET offerings to specific automotive needs ensures that each component delivers optimal performance and efficiency. Nexperia’s MOSFETs are essential in systems ranging from adaptive lighting and climate control to critical applications like electric power steering and braking systems. Innovations in packaging and silicon technologies enhance thermal performance and durability, vital attributes where reliability and space economy are most important.Nexperia upholds a zero-defect culture, which has been recognized through multiple supplier awards, reflecting their commitment to excellence. Impressively, the company has maintained a complaint rate of less than 0.05 complaints per million since 2019, emphasizing their relentless focus on quality.&nbsp;In addition to these innovations, Nexperia provides next-generation support tools for automotive engineers. Their interactive datasheets allow real-time adjustment of parameters like voltage, current, and temperature, instantly visualizing MOSFET behavior. This streamlines design workflows by eliminating manual calculations and circuit simulations. Advanced electrothermal MOSFET models also enable early-stage validation of circuit designs, helping identify EMI and EMC issues upfront.Nexperia's ongoing innovations and focus on quality support automotive manufacturers in developing more efficient, reliable, and cost-effective electronic systems. These advancements contribute to vehicles that offer improved safety, comfort, and environmental performance.Visit <a href="https://nexperia.com/mosfets" target="_blank">Nexperia's official website</a> to explore a range of advanced MOSFET solutions built for automotive electronics.<h2 dir="ltr">Conclusion</h2>Nexperia's ongoing commitment to innovation in MOSFET technology highlights the critical role these components play in improving vehicle performance, efficiency, and safety. By leveraging advanced materials and innovative designs, Nexperia ensures that automotive electronics meet stringent contemporary standards and are equipped for the evolving demands of tomorrow. As the shift towards more electric and autonomous vehicles continues, the need for reliable, efficient, and high-performance MOSFETs becomes increasingly apparent.<h2 dir="ltr">References</h2>[1] Nexperia. Driving solenoids in automotive applications Rev. 1.1 [Internet]. 3 Nov 2023. Available from:<a href="https://assets.nexperia.com/documents/application-note/AN50003.pdf" target="_blank">&nbsp;https://assets.nexperia.com/documents/application-note/AN50003.pdf</a>[2] Nexperia. MOSFET and GaN FET Application Handbook [Internet]. 19 Nov 2020. Available from:<a href="https://efficiencywins.nexperia.com/efficient-products/mosfet-and-gan-fet-application-handbook" target="_blank">&nbsp;https://efficiencywins.nexperia.com/efficient-products/mosfet-and-gan-fet-application-handbook</a>[3] Nexperia. Selection Guide: Discrete, MOSFET and GaN FET components, analog &amp; logic ICs [Internet], Available from: <a href="https://assets.nexperia.com/documents/selection-guide/Nexperia_Selection_guide_2023.pdf" target="_blank">https://assets.nexperia.com/documents/selection-guide/Nexperia_Selection_guide_2023.pdf</a>

Nexperia's automotive MOSFETs enhance innovation across both traditional and electric vehicles, expertly managing a wide array of applications from simple lighting to advanced electrification systems, ensuring high performance, reliability and superior efficiency in every aspect.

High-Performance MOSFETs Driving Excellence and Innovations in Automotive Electronics

Pneumatic & hydraulic systems control and convert energy into mechanical action by manipulating pressurized gases or fluids, respectively. Each system operates under distinct principles that suit various industrial applications, optimizing tasks with specific power and precision requirements.

Pneumatic vs Hydraulic Power Systems: Working Principles, Differences, and Selection Criteria

This impedance means the conductor can't sustain a consistent voltage level throughout its length. Loss of voltage through all or part of the circuit is measured as voltage drop.<h2>What Causes Voltage Drop?</h2>Voltage drop occurs normally when a current passes through an electrical cable. It results in the amount of voltage being reduced over a run of cable from input to output. This means that any electrical equipment will receive an input voltage below the value of the input supply. The level of voltage drop is also affected by passive elements in the circuits, such as other cables, connectors and contacts.The resistance and reactance increase proportionally as you increase the length of the cable. Voltage drop is, therefore, a recognised problem with long cable runs, like those you might need in larger buildings or extended properties. Voltage drop can also have a significant impact on your electrical equipment. Your motors may run too slowly, overheat and burn out. Your heaters wont heat as well as they should, and your lights might start to flicker or dim. This loss of voltage can easily be measured using a voltage drop calculator. You need to use this calculation for single-phase, line-to-line electrical circuits so you may properly size the conductors.<h2>How To Calculate Voltage Drop</h2>So, what causes voltage drop is impedance in the flow of current through a length of cable. The voltage drop will also be greater in proportion to the resistance. You can use a voltmeter to check the level of voltage reduction, which you connect between the points where you want to measure the voltage drop. If you connect loads in series, the total of all the voltage drops in AC resistive circuits and DC circuits should add up to the total amount of voltage applied to the whole circuit.<div data-elfsight-app-lazy=""><label for="lzb7vuz6">mV/A/m</label><input maxlength="30" type="text" autocomplete="off" value="0" data-dashlane-rid="9921708943f59e14" data-dashlane-classification="other"><label for="lzb7whm5">Design Current (Ib)</label><input maxlength="30" type="text" autocomplete="off" value="0" data-dashlane-rid="7ce7da15ec68f1e8" data-dashlane-classification="other"><label for="lzb7x67f">Cable Length (Metres)</label><input maxlength="30" type="text" autocomplete="off" value="0" data-dashlane-rid="c2cd3a39ce5fb03e" data-dashlane-classification="other">Voltage Drop0 Volts0 VoltsPanel only seen by widget owner<a href="https://dash.elfsight.com/apps/calculator?utm_source=clients&amp;utm_medium=user-panel&amp;utm_campaign=elfsight-icon&amp;utm_content=calculator&amp;utm_term=www.rowse.co.uk" target="_blank" title="Panel only seen by widget owner"></a><a href="https://dash.elfsight.com/widget/2fa9c142-d376-40ed-af06-7cae3c988543?utm_source=clients&utm_medium=user-panel&utm_campaign=edit-widget&utm_content=calculator&utm_term=www.rowse.co.uk" target="_blank">Edit widget</a>Views0%Share🔥Tell your customers about new website functionality!<a href="javascript%3Avoid(0)" target="_blank" title="Share on Facebook"></a><a href="https://twitter.com/share?url=www.rowse.co.uk&amp;via=elfsight&amp;text=Now%20my%20site%20is%20cool%20as%20ever%20with%20a%20widget%20by%20Elfsight%20from%20https://elfsight.com/" target="_blank" title="Share on Twitter"></a><a href="https://plus.google.com/share?url=www.rowse.co.uk" target="_blank" title="Share on Google+"></a></div>When using a voltmeter to measure the voltage drop, you should always be sure that the proposed measurement isn't beyond the range of the voltmeter. If you dont know how much voltage is in question, this can make it difficult to keep within the voltmeters range. If you do set out from this position, you should always go from the top and start with the highest range. Trying to measure a higher voltage than it can handle could cause damage to the voltmeter.You might occasionally have to measure a voltage drop between a specific point in your electrical circuit and some common reference point or ground. If this is the case, you should connect first to the circuits ground or common point, using the voltmeters black common test probe. The red test probe should only then be connected to the point in the circuit that you need to measure.<h2>Voltage Drop Formula</h2>When you want to calculate the percentage of voltage drop precisely for any cable length, size and current, you must know the exact resistance of your cable type. To simplify these calculations, you can use this formula to work it out:In this formula...<ul><li>X represents the voltage drop</li><li>mV/A/m stands for milliVolts per metre per Amp</li><li>Ib represents the design current</li><li>I represents the total length of the circuit cable conductor</li></ul>&nbsp;Therefore, an electrical conductor loses an amount of voltage for every metre it travels, measured in the number of millivolts (mV) for every amp of electrical power (design current) that flows through it. The whole calculation is then divided by 1,000 to get volts instead of millivolts.The design current represents the maximum current that you expect the circuit to use (watts/voltage). If you dont know this amount, you can go with the rating of the protective device, as the design current will never exceed this amount. In order to arrive at a percentage voltage drop for your circuit, you can multiply the amount of design current (amps) by the length of your cable (metres). Take the resulting number and divide it by the value shown in the table to get the percentage.The maximum amount of voltage drop permitted in the UK under BS7671 is 3% for lighting circuits (6.9V) and 5% for all other purposes (11.5V).<h2>How To Fix Voltage Drop</h2>As with any kind of pressure loss over distance, the amount of voltage drop you experience relates directly to the length of cable and circuit you are using. To compensate for this loss, you can try using larger diameter cables, which will offer less impedance to the flow of current. You could also opt for copper conductor cables, as these are less prone to voltage drop. Your costs will inevitably rise as you try to minimise the problem, because copper is more expensive, as are larger-diameter cables. Its therefore of great importance to calculate the voltage drop over various cable options to find the optimum size and type.<h2>Counteracting Voltage Drop</h2>Voltage drop in general causes the electrical load to work harder, as there is less voltage than there should be pushing the current. Each load device on your circuit can only operate properly when it receives its correctly rated voltage. Without sufficient voltage, an electrical device will present problems such as overheating motors, flickering lights or ineffective heaters. This means that they present a safety hazard and aren't working cost-effectively.Any length or size of cable you use has some innate resistance, and the voltage drop is unavoidable when you run a current through it. However, using a larger diameter cable will mean the voltage drop is less than using a small size. To keep within British Standard prescribed limits, and for optimal performance of your electrical equipment, this is often the simplest solution. It will greatly improve the functionality, reliability, and safety of your electrical installations.

If you force anything through a length of pipe or cable, the amount of power at the supply end will inevitably diminish by the time it gets to the exit. Electrical cables are no different. When electric current travels through cables, its flow is always impeded by the cable's inherent DC resistance.

What Causes Voltage Drop?

Power management refers to the process of controlling and optimizing the distribution and use of electrical power in a system. It is crucial to ensure that electronic devices operate efficiently, reliably, and within their power specifications. Effective power management reduces energy consumption, minimizes heat generation, extends battery life in portable devices, and ensures that all components receive the correct voltage and current.&nbsp;This is especially important in complex systems with multiple power rails and varying load conditions, which can impact overall performance and longevity.This 4-part webinar series, kicking off in early September, is designed to guide engineers from the fundamentals to the cutting-edge of power management. Each session is packed with practical tips and real-world examples to guide your knowledge and set you up for future success.&nbsp;These sessions are valuable for all engineers wanting to expand their power management knowledge and use of tools and techniques.&nbsp;In the first webinar, participants will learn how to kick off a solid power design and understand key design considerations such as parasitics and surge. The session will also tackle transients for a power source that stays within the rails.&nbsp;Following this, the next sessions will deepen in complexity, covering topics such as how to select the right power converter and comprehensively understanding the ADI Power Management Tool Suite to optimize designs.&nbsp;Each of the sessions is led by Larry Crosby, the Principal Engineer of Technical Marketing at Analog Devices. Crosby has worked in the electronics industry for over 40 years. Throughout his career, he has worked for a professional audio company, ATE equipment manufacturers, computer companies, and medical device companies. He has been responsible for writing test programs for automated test equipment (ATE) and designing analog hardware for all of his previous employers. His areas of expertise include linear circuits, data converters, low-noise and low-power circuits, as well as a wide variety of power conversion circuits.&nbsp;<div dir="ltr" align="left" id="isPasted"><table><tbody><tr><td style="width: 49.9398%;">Larry Crosby has worked in the Electronics industry for over 40 years. His career has taken him to a Professional Audio company, ATE equipment manufacturers, Computer companies and medical devices. He has held positions writing test programs for ATE, and designing analog hardware for all his former employers. Areas of expertise include linear circuits, data converters, low-noise and low-power circuits and a wide variety of power conversion circuits. Since 2006, Larry has worked for Linear Technology as an FAE supporting a wide variety of Broad Market customers, a role he continued after the merger with Analog Devices. Since 2018 he has been doing mentoring for Junior FAEs and creating training programs focused on Power circuits for the FAE community.&nbsp;</td><td style="null; width: 50.0000%;"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzI0OTQ2OTQxODkzLTE3MjQ5NDY5NDE4OTMucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" id="isPasted" class="fr-fic fr-dii"></td></tr></tbody></table></div><h3 dir="ltr">Why you should attend:</h3><ul><li dir="ltr">Learn key design considerations for power systems.</li><li dir="ltr">Discover how to select and optimize power converters.</li><li dir="ltr">Master the use of Analog Devices' Power Management Tool Suite.</li></ul><a href="https://event.on24.com/eventRegistration/EventLobbyServlet?target=reg20.jsp&eventid=4672972&sessionid=1&key=139BBC4A63EA1B32D8645F28D1F9DED8&groupId=5642749&partnerref=Supplyframe&sourcepage=register" target="_blank" rel="noopener noreferrer" class="button-main-action">Register for all the sessions here</a><h1 dir="ltr" id="isPasted">Power Management Fundamentals Session 1: Getting Started with Power Designs</h1>Date:&nbsp;Wednesday, September 04, 2024Time: 8:00 am PDT | 11:00 am EDT | 17:00 CEST<a href="https://event.on24.com/wcc/r/4672972/139BBC4A63EA1B32D8645F28D1F9DED8?partnerref=Supplyframe" target="_blank">Register here for the full series</a>Learn about Power Fundamentals from one of Analog Devices' Power experts. &nbsp;Get started by getting organized. &nbsp;Review power basics and circuit design techniques from input to output. Discover design choices to impact efficiency, solution size and cost. Join this 4 part series to learn the basics of Power design.Attendees will Learn:<ul><li dir="ltr">How to kick off a solid power design</li><li dir="ltr">Design considerations - parasitics and surge</li><li dir="ltr">Tackle transients for a power source that stays within the rails</li></ul><h2>Power Management Fundamentals Session 2: Which Power Converter is the Right One?</h2>Date:&nbsp;Tuesday, September 17, 2024Time:&nbsp;8:00 am PDT | 11:00 am EDT | 17:00 CEST<a href="https://event.on24.com/wcc/r/4672982/BDD0187139598F5E033B9D2F20421930?partnerref=Supplyframe" target="_blank">Register here for the full series</a>Join us as we learn about various types of Power regulators. &nbsp;Get tips on maximizing power devices while staying within the datasheet parameters. Evaluate the tradeoffs that come with integrating more functionality into one part.Attendees will Learn:<ul><li dir="ltr">How to use various Power Converters from LDOs to Switching Regulators</li><li dir="ltr">Design with Ćuk &amp; Buck-Boost Inverting Regulators</li><li dir="ltr">Discover loop control topologies and compensation techniques</li><li dir="ltr">Determine the right level of integration for your power design</li></ul><hr><h1 dir="ltr">Power Management Fundamentals Session 3: Use the Tools, Save on Debug</h1>Date:&nbsp;Tuesday, September 24, 2024Time:&nbsp;8:00 am PDT | 11:00 am EDT | 17:00 CEST<a href="https://event.on24.com/wcc/r/4673521/A043EC9B0AAEDD31D811FA9126A1A78B?partnerref=Supplyframe" target="_blank">Register here for the full series</a>Discover how Analog Devices' complete set of power management tools makes designing power systems and circuits easier. Develop system-level power trees, optimize each supply rail, and fully simulate your circuit so that you get the most out of your design.Attendees will Learn:<ul><li dir="ltr">How to leverage the Power Management Tool Suite at every step of your design</li><li dir="ltr">Optimize your power rails for critical load device parameters</li><li dir="ltr">Balance efficiency and load with switching frequency to optimize your design</li></ul><hr><h1 dir="ltr">Power Management Fundamentals Session 4: More Tools for a Better Result</h1>Date:&nbsp;Tuesday, October 01, 2024Time:&nbsp;8:00 am PDT | 11:00 am EDT | 17:00 CEST<a href="https://event.on24.com/wcc/r/4673525/BE655DF79F59A7F48972B60C38C2E76D?partnerref=Supplyframe" target="_blank">Register here for the full series</a>Using Analog Devices' complete set of power management tools, start with part selection and then work through a Power Tree design live. &nbsp;Simulate a power circuit in minutes and watch how passive component choices can alter the power supply characteristics. &nbsp;Quickly modify component selections to optimize value and performance.Attendees will Learn:<ul><li dir="ltr">Easily swap circuit elements and test for performance</li><li dir="ltr">Capacitors and Inductors - not as simple as they seem</li><li dir="ltr">Use a tool to help figure out which FET is right for your design</li></ul><h1 dir="ltr">More on Analog Devices' Power Management Tools&nbsp;</h1>Analog Devices' Power Management Tools suite helps streamline the design and optimization of power systems. It includes tools like LTpowerCAD® for power supply design, LTspice® for circuit simulation, and LTpowerPlanner for system-level power architecture design. These tools allow users to design, simulate, and validate power circuits efficiently, optimizing for performance and component selection to meet specific application requirements.<a href="https://event.on24.com/wcc/r/4673525/BE655DF79F59A7F48972B60C38C2E76D?partnerref=Supplyframe" target="_blank" rel="noopener noreferrer" class="button-main-action">Register for the webinar here</a>

This 4-part webinar series offers practical tips and expert guidance on power basics and circuit design techniques, making it an essential resource for anyone looking to optimize their power system designs.

Power Management Fundamentals: New 4 Part Webinar Series

A stator is the stationary part of an electric motor or generator, consisting of coils or windings mounted on an iron core, designed to create a magnetic field when electric current flows through it. Explore the fundamentals, advancements, and applications of stators in modern engineering.

What is a Stator? A Comprehensive Guide for Engineers

As the demand for sustainable energy solutions intensifies, the role of electric vehicles (EVs) extends beyond transportation. The concept of bidirectional charging is becoming increasingly important as it allows electric vehicles (EVs) to not only receive power but also to supply it back to the grid or other connected systems when needed. This technology is significant because it helps ensure grid stability and sustainability by effectively turning EVs into mobile energy resources.In this article, we explore bidirectional charging, detailing its integration with modern EVs, and introduce the <a href="https://components.omron.com/us-en/products/relays/G9KB" target="_blank" rel="noopener noreferrer">Omron G9KB-E high-capacity power relay.</a><h1 dir="ltr">Foundations of bidirectional charging</h1>bidirectional charging is a technology that equips EVs with the capability to both receive and supply electrical energy. This system integrates into the vehicle's charging infrastructure, allowing the EV battery to act as a dynamic energy storage unit. Unlike traditional charging, which is a one-way flow of electricity from the grid to the vehicle, bidirectional charging facilitates a reversible flow, where energy can be returned to the grid or directed elsewhere as needed.The mechanics of bidirectional charging involve several key components: an inverter, a bidirectional charger, and intelligent software that manages the flow of electricity. The inverter is crucial as it converts the DC power stored in the EV’s battery into AC power that can be fed back into the grid. Conversely, it also handles the conversion of AC from the grid into DC to charge the vehicle’s battery.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzE4MTk1NTQyNjA2LWltYWdlNy5qcGciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width: 100%px;" class="fr-fic fr-dib" alt="EV-bidirectional-charging-block-diagram-concept">Block diagram illustrating the concept of bidirectional charging for EVsA critical aspect of this technology is regulating power flow, which is controlled by sophisticated software algorithms. These systems ensure that energy transfer is efficient and occurs at optimal times, such as during periods of low demand when energy prices are lower and the grid is less strained. This capability requires a seamless and continued interaction between the vehicle, charging station, and the broader power grid, necessitating robust communication protocols to maintain synchronization and ensure safety. Bidirectional technology broadens the functionality of EVs and enhances the overall resilience and efficiency of the electrical grid. The following sections will explore these aspects in more detail.<h2 dir="ltr">Bidirectional charging applications</h2>Integrating bidirectional charging with EVs is a complex process that enhances the vehicle's ability to manage energy. This integration can be configured for many applications, each serving different needs.&nbsp;The core bidirectional power applications include:<ul><li dir="ltr">Vehicle to Load (V2L):&nbsp;Allows EVs to power external devices, useful for camping or emergencies, utilizing the EV's battery as a portable power source.</li><li dir="ltr">Vehicle to Home (V2H): Enables EVs to power homes during peak hours, reducing electricity costs by storing energy during off-peak times.</li><li dir="ltr">Vehicle to Building (V2B): Similar to V2H but powers entire buildings, offering emergency backup during outages.</li><li dir="ltr">Vehicle to Vehicle (V2V): Allows one EV to charge another, useful in emergencies when no charging stations are available.</li><li dir="ltr">Vehicle to Grid (V2G): Allows EVs to feed energy back into the grid, stabilizing it during peak demand or sudden spikes. Standardized under ISO 15118, V2G enables secure, efficient interaction between EVs and the grid.[1]</li></ul>Each of these methods leverages EVs' inherent storage capability to distribute electricity where it's needed most, thereby enhancing the overall efficiency of our energy use. As these technologies mature, they promise to make EVs not just consumers of power but critical components of our energy infrastructure.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzE4MTk0MzQyOTA2LWltYWdlMy5qcGciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width: 100%px;" class="fr-fic fr-dib" alt="V2H-V2B-commercial-EVs">V2H &amp; V2B tech can enable even commercial EVs to become mobile powerhouses, potentially providing power sources for buildings during high demand/power outages. Image credit: Heliox Energy<h2 dir="ltr">Benefits of Bidirectional Charging</h2>Bidirectional charging offers a multitude of advantages that contribute to both individual cost savings and broader environmental benefits:Cost Savings: By utilizing bidirectional charging, EV owners can operate their vehicles more economically. Charging an EV during off-peak hours when electricity rates are lower and then using that energy during peak hours can significantly reduce electricity bills. Some estimates suggest that users of this technology can save approximately $150 annually.[2] The amount may seem very modest at present, but as the technology matures, these savings are very likely to increase.Emergency Power:&nbsp;In the event of a power outage, bidirectional charging allows EVs to supply power back to the home or grid, serving as a backup power source. This can be crucial for maintaining critical functions in residential and commercial settings during emergencies.Grid Stability:&nbsp;This technology plays a crucial role in stabilizing the electrical grid by providing energy back during demand peaks. Instead of solely relying on grid-supplied electricity during high-demand periods, energy can be sourced from EVs, which act as mobile storage units. This reduces the risk of grid overload and enhances the reliability of the power supply.Renewable Energy Integration: Bidirectional charging facilitates greater use of renewable energy by storing excess generated energy in EV batteries during peak production times. This stored energy can then be used when solar or wind production is low, smoothing out the fluctuations in renewable energy availability.Reduced Emissions: By improving energy efficiency and promoting the use of renewables, bidirectional charging may help reduce a grid's overall carbon footprint. As more renewable energy sources are integrated into the grid, the reliance on fossil fuels decreases, leading to lower greenhouse gas emissions.These benefits showcase how bidirectional charging supports individual EV owners and contributes significantly to creating a more resilient, efficient, and sustainable energy ecosystem.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzE4MTk0MzcxNjU0LWltYWdlNC5qcGciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width: 100%px;" class="fr-fic fr-dib" alt="bidirectional-charging-for-V2H">Bidirectional charging revolutionizes energy management by providing cost savings, enhancing grid stability, and integrating renewable energy sources. Image credit: EVbox<h1 dir="ltr">Bidirectional Charging with Omron G9KB-E High-Capacity Power Relay</h1>Bidirectional relays play a crucial role in managing power flow in charging systems, enabling efficient energy transfer between electric vehicles and the grid or home. This capability allows EVs to charge from the grid and supply stored energy back, unlocking a range of V2X applications. Notably, relays like the Omron G9KB-E can replace two unidirectional relays, simplifying system design, reducing components, and enhancing reliability.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzE4MTk0Mzg3MTM0LWltYWdlMi5wbmciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width: 100%px;" class="fr-fic fr-dib" alt="unidirectional-relays-vs-omron-bidirectional-relay">The Omron G9KB-E relay can replace two unidirectional relays, simplifying design and enhancing reliability. Image credit: OmronBy managing both incoming and outgoing power flow with a single relay, the G9KB-E ensures a more streamlined and effective control mechanism. Through precise control of power flow, the relay helps maintain stability and efficiency within the energy system, preventing overloading and ensuring desired power distribution.<h2 dir="ltr">Benefits of Using Bidirectional Relays in EV Charging Stations</h2>In bidirectional charging systems, maintaining safe and efficient energy flow is critical. Relays are crucial components in managing power flow and safeguarding the charging system. Their functionality is integral to the system's overall reliability, ensuring the safety of both the vehicles and users. Here are some ways in which relays enable the charging process:<ul><li dir="ltr">Bidirectional Power Flow Control:&nbsp;Relays can potentially manage the flow of power in both directions during bidirectional charging (EV to grid or home) by selectively switching circuits.</li><li dir="ltr">Component Reduction: Bidirectional relays can replace two unidirectional relays, streamlining system design and lowering costs.</li><li dir="ltr">Safe Connection/Disconnection: Relays act as a physical switch, allowing the charger to safely connect and disconnect the EV's battery. This ensures no power flows when the car is not plugged in or during emergencies.</li><li dir="ltr">Isolation and Switching: In chargers with variable voltage outputs for different EV types (e.g., high-voltage for trucks and low-voltage for cars), relays provide isolation between these outputs, preventing accidental mixing of voltages.</li><li dir="ltr">Emergency Shutdown: In case of fault conditions like ground faults, current surges, overheating, overcharging, or short circuits, relays can quickly interrupt the power flow, protecting the charger, EV battery, and users.</li></ul><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzE4MTk0NDAxMDQ2LWltYWdlMS5qcGciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width: 100%px;" class="fr-fic fr-dib" alt="block-diagram-EV-charging-station">Block diagram of an EV charging station highlighting the critical function of Omron G9KB-E relays in managing the power supply to the EV battery, ensuring safe and efficient charging.<h2 dir="ltr">Omron G9KB-E High-Capacity Bidirectional Power Relay</h2>The G9KB is a family of high-capacity power relays by Omron that are vital components in enhancing energy management for bidirectional charging systems. The G9KB relays are designed for both standard and high-power applications, making them a versatile choice for various energy systems.&nbsp;The Omron G9KB-E, a Single-Pole Single-Throw Normally-Open (SPST-NO) power relay, is the high-capacity model of the G9KB series. It can handle up to 800 VDC and 100 A, making it ideal for demanding energy management tasks.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzE4MTk0NDEwNjE2LWltYWdlNS5wbmciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width: 100%px;" class="fr-fic fr-dib" alt="omron-g9kb-e">Omron G9KB-E high-capacity power relay. Image credit: OmronHere are some key features of the Omron G9KB-E high-capacity power relay:<ul><li dir="ltr">Max Switching Voltage: Up to 800 VDC, making it suitable for high-voltage applications.</li><li dir="ltr">Max Switching Current:&nbsp;Capable of handling up to 100 A, ensuring it can manage substantial power loads.</li><li dir="ltr">Bidirectional switching: Bidirectional switching feature to replace two unidirectional relays with just one for bidirectional current applications.</li><li dir="ltr">Wide Operating Temperature Range: Operates efficiently from -40°C to 85°C, making it reliable in diverse environmental conditions.</li><li dir="ltr">Durability: The relay provides high electrical durability, guaranteeing at least 6,000 operations at 800 VDC and 18 A, 300 operations at 500 VDC and 100 A, 100 operations at 600 VDC and 100 A, and 10 operations at 800 VDC and 50 A (under specified measurement conditions of 1 second ON, 9 seconds OFF at 85°C and 25% to 75% relative humidity conforming to the conditions of JIS C 5442 test methods). This range of durability ensures reliable performance under a variety of load conditions.</li><li dir="ltr">Safety standard compliance:&nbsp;The relay meets safety standards such as UL 60947-4-1 and EN IEC 61810-10, designed for solar and energy storage system components.</li><li dir="ltr">Effortless PCB Installation: Safer and lighter than traditional gas-filled relays, with PCB mountings that eliminate the need for screw terminals and reduce manual labor costs.</li><li dir="ltr">Maximized efficiency: Low contact resistance for minimal voltage drop and heat generation to enhance system efficiency.&nbsp;<iframe id="6673055bd6d73867774c6178" width="250" class="specs-iframe" height="440" src="https://wevolver.com/iframe/specs/g9kb-e-pcb-power-relays-high-capacity-model?iframe=true" frameborder="0" scrolling="no" data-lf-form-tracking-inspected-kn9eq4roawkarlvp="true" data-lf-yt-playback-inspected-kn9eq4roawkarlvp="true" data-lf-vimeo-playback-inspected-kn9eq4roawkarlvp="true"></iframe></li></ul><h2 dir="ltr">Further applications of the G9KB-E Relay</h2>The G9KB-E power relay is instrumental in the practical implementation of bidirectional charging, significantly enhancing these systems' overall efficiency and reliability. Its role in facilitating smoother and safer energy transitions makes it a key component in advancing smart energy management solutions.While we have focused on its critical function in EV bidirectional charging, the versatility of the G9KB-E Relay allows it to be used in various other settings, including:<ul><li dir="ltr">Energy Storage Systems: The relay is integral in systems that store and manage renewable energy.</li><li dir="ltr">V2X Applications:&nbsp;It supports various vehicle-to-everything (V2X) interactions, including V2H, V2B, etc.</li><li dir="ltr">DC Household Appliances: The relay can also be adapted for use in direct current appliances within a smart home environment.</li></ul>For more detailed information on the G9KB-E power relay or to inquire about purchasing options, interested parties are encouraged to visit the <a href="https://components.omron.com/us-en/products/relays/G9KB" target="_blank">product information page</a>.&nbsp;<h1 dir="ltr">Conclusion</h1>In conclusion, bidirectional charging represents a significant advancement in energy management, leveraging electric vehicles as mobile energy sources. Despite its challenges, such as technical complexity and battery wear, the benefits, including cost savings, reduced emissions, and increased grid stability, are substantial.&nbsp;Continued innovation and supportive regulations are essential for its advancement. The Omron G9KB-E high-capacity power relay plays a crucial role in enhancing the efficiency and safety of bidirectional charging systems, making it a key component in the transition to a more sustainable energy future.<h1 dir="ltr">References</h1>[1] ISO 15118-1:2019, Road vehicles — Vehicle to grid communication interface, ISO, [Online], Available from: <a href="https://www.iso.org/standard/69113.html" target="_blank">https://www.iso.org/standard/69113.html</a>[2] City-Wide Modeling of Vehicle-to-Grid Economics to Understand Effects of Battery Performance, ACS Sustainable Chem. Eng. 2021, 9, 44, 14975–14985, Publication Date:October 26, 2021, <a href="https://doi.org/10.1021/acssuschemeng.1c05490" target="_blank">https://doi.org/10.1021/acssuschemeng.1c05490</a>&nbsp;[3] OMRON Launches "G9KB" Relay for High Capacity Electricity Storage Systems, 11 May 2022, Omron, [Online], Available from: <a href="https://www.omron.com/global/en/media/2022/05/c0511.html" target="_blank">https://www.omron.com/global/en/media/2022/05/c0511.html</a>

Bidirectional charging introduces exciting possibilities for EVs to power entire buildings but necessitates meticulous control of energy flow. Components like high-capacity relays play a critical role, ensuring safe and efficient power transfer through precise switching and circuit isolation.

Enabling bidirectional charging for electric vehicles with high-capacity power relays

Digital platforms have profoundly transformed the design process for cobot motor drives, enabling engineers to streamline workflows, enhance precision, and rapidly adapt to the evolving demands of the industrial landscape.

Streamlining Cobot Design with Digital Platforms and Online Resources

IntroductionBoard-mounted DC/DC converters can now be rated in kW, and even with high-efficiency levels, they dissipate significant power. Cross-coupling of heat from loads and other components in close proximity means that prediction of the DC/DC internal temperature rise is challenging. This article discusses some hardware and software tools available to make the systems designer&rsquo;s task easier, using <a href="https://flexpowermodules.com/" rel="noopener noreferrer" target="_blank">Flex Power Modules</a> as an example.&nbsp;Demands of DC/DC convertersBack in the day, board-mounted DC/DC converters for supply rails in digital systems were so large for their rated power that they were derogatorily called &lsquo;bricks&rsquo;. It was a bit unfair, as they were never as big as even the smaller building bricks, but they certainly took up substantial, valuable board space. One of the main reasons for their size was the need to provide sufficient surface area for cooling, which often relied on convection or incidental system airflow. Over the years, improved efficiency and consequent lower losses have eased the situation, allowing smaller parts, but at the same time, load power demanded has increased dramatically, particularly in typical data center applications, with the emergence of &lsquo;the cloud&rsquo;, AI, and high-performance computing.&nbsp;Additionally, as voltages drop and currents increase, converters need to be fitted ever closer to their loads to avoid voltage and power loss in connections, and this has made size more of an issue with sometimes thousands of CPU connections having to mix in with the power traces. At the same time, this puts the converter in a hotter environment. When the load was 100 W, and the DC/DC dissipated 15 W a few inches away, they could be cooled separately and thermal interactions largely neglected, but when the figures are more like 1 kW and 50 W with little physical separation, the DC/DC and load must be treated as thermally inter-dependent.&nbsp;DC/DC and load must be considered as one thermal systemTaking the DC/DC and load together, cooling can be achieved in a combination of ways, from simple air convection to cold walls and fluid immersion, but typically, forced air is common for cost sensitive commercial and industrial applications. However, there is often no space for a heatsink to be attached to the DC/DC, so the surface from which heat is removed by airflow is limited. It&rsquo;s therefore, common to rely on heat transfer through the converter pins to the circuit board, which anyway has wide copper traces to cope with the high currents typically seen. The air flow then transfers heat from the DC/DC and the surface of the PCB, which itself could also be heated by other components.Things might be relatively simple if heat dissipation in the load and power converters were constant, but modern data processing systems &lsquo;throttle back&rsquo; and accelerate tasks to make efficient use of processing capability and minimize average power draw. Voltage rails are &lsquo;dynamically scaled&rsquo; to achieve this, so DC/DCs not only see wide variation in loads but also other operating conditions &ndash; input and output voltages and air temperature.&nbsp;These variations in turn, affect the converter efficiency, changing heat levels to be dissipated. In the most &lsquo;finely tuned&rsquo; systems, peak loads are not expected to be thermally sustainable over longer periods without exceeding maximum component internal temperatures, so both the load and DC/DC are typically characterized with a continuous and peak load rating, which has to be carefully monitored so as not to exceed critical temperatures. Flex Power Modules&rsquo; <a href="https://flexpowermodules.com/products/bmr491" rel="noopener noreferrer" target="_blank">BMR491 series</a> (Figure 1) is an example of a product rated at 1540&nbsp;W as a thermal limit, but at 2450&nbsp;W peak for a limited time, depending on starting temperature.&nbsp;<img border="0" width="340" src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjg2MDgxNzUwNjEwLTE2ODYwODE3NTA2MTAuanBlZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" class="fr-fic fr-dii">Figure 1: A DC/DC with high peak to continuous power rating &ndash; the BMR491Simulation is the way forwardUnderstandably, with all the interacting variables, traditional analytical methods to predict critical temperatures in components are not practical and simulation is the way forward.For accurate results, electrical and thermal characteristics of the DC/DC converter must be known and this is provided by the <a href="http://www.flexpowermodules.com/flex-power-designer" target="_blank">Flex Power Designer</a> tool for the company&rsquo;s DC/DCs.&nbsp;The software allows a system to be configured from drop-down selections and will calculate individual device and system efficiency, power dissipated and hot-spot temperature from user-specified conditions. Particularly, airflow rate can be defined along with air temperature, PCB thickness, copper coverage and its maximum allowed temperature, which will often be a limiting factor. See example screenshot Figure 2. The tool takes account of the way the device efficiency changes at different temperatures from established test data and will update results &lsquo;on-the-fly&rsquo;.<img border="0" width="567" src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjg2MDgxNzUwNjQyLTE2ODYwODE3NTA2NDIuanBlZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" class="fr-fic fr-dii">Figure 2: Example screenshot of the Flex Power Designer Tool showing, in this case, DC/DC module hot-spot temperature v. air flow rate&nbsp;&nbsp;Seeing capability in 3DWhile the simulation tool shows actual results under specified conditions, the data sheets also provide traditional power derating graphs, for example with air temperature and flow rate. For this, assumptions must be made about the size and characteristics of any attached heatsink and PCB as well as air flow direction. For a more accurate indication, Flex Power Modules takes this a step further with &lsquo;3D&rsquo; representations of derating with specified baseplate and pin temperatures (Figure 3). From qualification data, Flex Power Modules has also accurately characterized their parts for the relationship between these interacting hot-spots and maximum allowable junction temperatures, so that users can be confident that if these values are not exceeded at the given power, maximum utilization of the part without undue stress is achieved.<img border="0" width="529" src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjg2MDgxNzUwNjYyLTE2ODYwODE3NTA2NjIuanBlZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" class="fr-fic fr-dii">Figure 3: A typical 3D derating graph, for a device within their BMR491 seriesIntegrating DC/DC thermal simulation with other componentsAlthough DC/DCs might be a major source of heat on a PCB, there will be other components contributing as well, not least those acting as loads on the converter. Their total interaction can be simulated in programs such as FloTherm. Flex Power Modules offers CAD models for their DC/DCs in STEP format, which can be imported into FloTherm through the FloEDA bridge for a full system thermal simulation. The models are finely detailed to include the heat contributing elements and the characteristics of each DC/DC PCB layer, including dielectric and vias. Flex Power Modules provides the power dissipated for each source of heat under various operating conditions and defines the temperature monitor points. As a check, the DC/DC FloTherm model is calibrated against wind-tunnel tests such that simulated temperature rises are typically within 2&deg;C of the measured values.Peak load effectsMany of Flex Power Modules&rsquo; DC/DCs have a peak load capability, for example their <a href="https://flexpowermodules.com/products/bmr313" rel="noopener noreferrer" target="_blank">BMR313 series</a>, rated at 1 kW continuous and 3 kW peak. With a short transient load, the junction temperature of the device is allowed to reach its maximum rated, typically 150&deg;C or 175&deg;C, and the duration allowed is set by the local thermal capacitance of the power devices. The tools available to avoid device stress are based around local temperature sensors and current measurements, depending on the peak load value. For example, with the, an overload of 3.4 kW or higher causes a fast hardware shutdown within a few microseconds with a &lsquo;HW_FAULT&rsquo; signal generated. Above 2.6 kW, a slower hardware timed shutdown operates within one or two milliseconds with an &lsquo;OC-FAULT&rsquo; signal. Up to 1.8 kW, the shutdown is temperature based, with an alert signal generated on a dedicated pin, requesting the load to reduce power if possible.&nbsp;Figure 4&nbsp;shows the levels and timings.<img border="0" width="416" src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjg2MDgxNzUwNjgxLTE2ODYwODE3NTA2ODEuanBlZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" class="fr-fic fr-dii" style="width: 758px;">Figure 4: The BMR313 continuous, peak and transient peak protection schemeThe actual junction temperatures reached during peak power events depends naturally on the starting point, and maximum power available with safe operation can be achieved by estimating temperature from current levels and known device characteristics. This is implemented in the&nbsp;<a href="https://flexpowermodules.com/products/bmr350" rel="noopener noreferrer" target="_blank">BMR350</a>&nbsp;product for example, where current is monitored monitored<ins cite="mailto:jess%20miley" datetime="2023-06-06T21:45" style="background-color: transparent;">,</ins>&nbsp;and the signal filtered with an &lsquo;Exponential Moving Average&rsquo; (EMA) method. This can be extended with a &lsquo;dual EMA&rsquo; scheme with different weightings to additionally emulate the effects of varying cool-down periods between peak load pulses.&nbsp;A comprehensive set of design tools for maximum performance and minimum stressThe combination of <a href="https://flexpowermodules.com/flex-power-designer" rel="noopener noreferrer" target="_blank">Flex Power Designer</a> software, FloTherm models and hardware protection provides a tool set enabling rapid and efficient design, modelling, and monitoring of complex power conversion systems. Choosing modules from the Flex Power Modules range, thermal performance can be optimized at the DC/DC and system level for minimum stress while achieving maximum power density and value. Visit <a href="https://flexpowermodules.com" rel="noopener noreferrer" target="_blank">Flex Power Modules</a> to explore the products and design tools available.

Meeting the challenges of thermal design for DC/DC converters with the right combination of hardware and software.

Thermal Design Tools for System Integration of DCDC Converters

Electric Motors - AC Servo Motor, DC Brushless Motor, and Stepper Motor

In this article, we will delve into the key factors that differentiate stepper and servo motors, including their operating principles, torque characteristics, control methods, and suitability for different applications.

Stepper vs Servo Motors: Mastering Motor Selection for Precision Engineering

This is the sixth article in an 8-part series featuring articles on Innovations in Electric and Autonomous Vehicles. The series presents an insight into the developments and challenges in the automotive sector as it undergoes massive transformations with the arrival of electric and self-driving vehicles. This series is sponsored by Mouser Electronics. Through the sponsorship, Mouser Electronics shares its passion for technologies that enable smarter and connected applications.The cost of Li-ion, the leading electric vehicle (EV) battery chemistry technology, will soon settle at a mature market value due to market dominance.[1] With that, there is an opportunity for alternate chemistry innovation to gain a share of the battery segment. One such chemistry, solid-state batteries, is poised to emerge as the leading chemistry for EV batteries.In this article, we present a comparison between the commonly used Li-ion batteries and the (relatively) new solid-state batteries for EVs. We also analyze some barriers preventing the mass adoption of the new battery technology.<h1 dir="ltr">Li-ion vs. Solid-State Electrolytes for Battery Electric Vehicles</h1>Li-ion is still leading the market for liquid-state electrolytes. But Li-ion is not without challenges: The chemistry carries higher costs as skyrocketing demand outstrips supply. In addition, there is an opportunity to improve the top safety concern of flammable liquid catching fire. Safety is one of the most critical success criteria for EVs to inspire public confidence, so the industry and safety regulators are searching for how to reduce the flammability risk.Solid-state batteries (using lithium metal as one of its elements) address the most pressing safety challenges of Li-ion. They are more stable and contain a higher energy density than Li-ion. In addition, solid-state comes from readily available materials, which reduces the need to mine. It also offers lower flammability, faster charging, and extended range.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjc2MTMzMzE1MDgzLTE2NzYxMzMzMTUwODMucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" width="720" height="288" class="fr-fic fr-dii">Fig. 1: Li-ion vs. Solid State BatteriesBarriers to the Wide-Scale Adoption of Solid-state Electrolytes for Electric VehiclesWith the advantages of safety, charge time, performance, and availability, solid-state is the future of EV batteries. However, there remain a few barriers to wide-scale adoption for battery developers.&nbsp;First, solid-state batteries will carry a higher development cost due to a lack of existing capital to produce mass quantities.There are also gaps in the solid lithium electrolyte material that degrade battery performance and service life when implemented into Battery Electric Vehicles (BEVs).&nbsp;In addition, solid-state batteries are prone to cracking, and it is best to charge them at 60&deg;C for optimal performance.Solid-state EV batteries are not yet mass-produced. As with any development material, optimizing the manufacturing process to scale profitably is essential. As a result, manufacturing challenges through the lack of experience with solid electrolyte materials would substantially delay wide-scale adoption. In addition, these challenges could shut down the EV battery plant, negatively impacting the public&#39;s first interaction with the new battery chemistry.To address development costs, automakers could vertically integrate to cut development costs and decrease supply risks, creating resiliency between original equipment manufacturers (OEMs) in the face of supply shortages. Their goal is to find a better solution for Li-ion batteries while reducing solid-state manufacturing costs.Having said that, OEMs are already shifting development to solid-state, given all their benefits. Adoption has already started: Toyota announced it will invest $13.5 billion by 2030 into solid-state batteries, and a group including Volkswagen, Ford, and BMW announced solid-state initiatives in the coming years.[2]<h1 dir="ltr">Conclusion</h1>Solid-state batteries address the flammability safety concerns with liquid-state batteries, charge faster, and provide a more extended driving range. Commissioning the capital and ramping supply of the batteries will aid the transition from liquid- to solid-state, preparing EVs for long-term success and massive consumer adoption.This article is based on an e-book by Mouser Electronics. It has been substantially edited by the Wevolver team and Electrical Engineer <a href="https://www.wevolver.com/profile/ravi.rao" target="_blank">Ravi Y Rao</a>. It&#39;s the sixth article from the Innovations in Electric and Autonomous Vehicles Series. Future articles will introduce readers to some more trends and technologies transforming the automotive sector.The <a href="https://www.wevolver.com/article/innovations-in-electric-and-autonomous-vehicles" target="_blank">introductory article</a>&nbsp;presented the different topics covered in the Innovations in Electric and Autonomous Vehicles Series.The <a href="https://www.wevolver.com/article/autonomous-and-electric-vehicles-the-future-of-mobility/" target="_blank">first article</a>&nbsp;discussed the present state of autonomous vehicles.The <a href="https://www.wevolver.com/article/cutting-down-emissions-with-mobility-as-a-service/" target="_blank">second article</a>&nbsp;explains MaaS and how improvements in automotive technologies are speeding up its adoption.The <a href="https://www.wevolver.com/article/a-deep-dive-into-the-new-v2x-and-cellular-v2x-architectures-based-on-5g/" target="_blank">third article</a>&nbsp;takes a look at how the 3GPP intends to use 5G in V2X applications with significant advantages over current dedicated short-range communication or other Cellular-V2X proposals.The <a href="https://www.wevolver.com/article/driver-monitoring-systems-for-ensuring-driver-alertness/" target="_blank">fourth article</a>&nbsp;explains Driver Monitoring Systems (DMS) and their role in reducing the possibility of mishaps due to human errorsThe <a href="https://www.wevolver.com/article/the-state-of-electric-vehicles-in-2023-trends-in-the-development-and-adoption-of-electric-vehicles/" target="_blank">fifth article</a>&nbsp;examines some of the ways EV technologies will evolve, and some of the obstacles they need to overcome before the automotive industry can transition to fully electricThe <a href="https://www.wevolver.com/article/solid-state-vs-li-ion-which-battery-tech-is-better-for-electric-vehicles/" target="_blank">sixth article</a>&nbsp;discusses solid-state batteries, a promising alternative to conventional Li-ion batteriesThe <a href="https://www.wevolver.com/article/active-noise-cancellation-in-electric-and-autonomous-vehicles/" target="_blank">seventh article</a>&nbsp;explains active noise cancellation and why it&rsquo;s a very effective solution for eliminating noises in automobilesThe <a href="https://www.wevolver.com/article/next-generation-vehicles-need-safe-human-machine-interfaces/" target="_blank">final article</a>&nbsp;focuses on Human Machine Interfaces, the sleek and stylish dashboards that are changing the way we interact with cars<h1 dir="ltr">About the sponsor: Mouser Electronics</h1>Mouser Electronics is a worldwide leading authorized distributor of semiconductors and electronic components for over 1,200 manufacturer brands. They specialize in the rapid introduction of new products and technologies for design engineers and buyers. Their extensive product offering includes semiconductors, interconnects, passives, and electromechanical components.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjc2MTMzMzM3OTk1LWltYWdlMi5qcGciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width: 300px;" class="fr-fic fr-dib"><h1 dir="ltr">References</h1>[1] David L. Chandler, &lsquo;The reasons behind lithium-ion batteries&rsquo; rapid cost decline&rsquo;, MIT News, 22nd November 2021, [Online], Available from: <a href="https://news.mit.edu/2021/lithium-ion-battery-cost-1122" target="_blank">https://news.mit.edu/2021/lithium-ion-battery-cost-1122</a>[2] Tim Kelly, &lsquo;Toyota to spend $13.5 bln to develop electric vehicle battery tech by 2030&rsquo;, Reuters, [Online], Available from: <a href="https://www.reuters.com/business/autos-transportation/toyota-spend-over-135-bln-ev-batteries-by-2030-2021-09-07/" target="_blank">https://www.reuters.com/business/autos-transportation/toyota-spend-over-135-bln-ev-batteries-by-2030-2021-09-07/</a>

Article #6 of Innovations in Electric and Autonomous Vehicles Series: Getting the capital equipment in place and ramping up the supply of batteries will help transition the market from liquid- to solid-state. Industry and consumers will both benefit.

Solid-State vs. Li-ion: Which Battery Tech is better for Electric Vehicles?

More than 20 years ago, a team set out to solve a problem: How do we reduce power loss and help reduce MOSFET size at the same time? LFPAK was the answer - and it changed everything.  

A story of innovation: How LFPAK revolutionized an industry.

This is the final article in an 8-part series featuring articles on Power Management for Tomorrow’s Innovations. The series focuses on power management and optimization techniques for modern electronic systems. This series is sponsored by Mouser Electronics. Through the sponsorship, Mouser Electronics shares its passion for technologies that enable smarter and connected applications.One of the biggest hurdles in increasing the adoption of Internet of Things (IoT) devices today is battery life. IoT devices running out of juice frequently is not only annoying for users but can have devastating effects in industrial space. As research continues to improve the charge-holding capacity of batteries, power converters must also evolve to optimize the use of all the available energy.This article presents a specific IoT power management solution for small, portable gadgets while also reviewing its shortcomings. We then introduce a nano-Power boost converter that overcomes these shortcomings while ‘operating on fumes’ down to minimal amounts of residual battery energy.<h2 dir="ltr">Typical Power Solution for Small IoT Products</h2>To understand the power needs of a typical small IoT product, let’s consider the example of a wearable heart monitoring patch. A wearable heart monitoring patch is a tiny device that must last for a long time; hence minimization of the size and power dissipation is crucial.&nbsp;Such devices can be powered by a 100mAh alkaline button cell and can consume around 100µA in operation. In such a scenario, the device may last three weeks. On the other hand, in shutdown mode, the device may need to last up to three years, which requires a leakage current of 4µA or less. A typical voltage regulator, with a leakage current of 0.2µA and a total quiescent current of 10µA, could rob 1.8 months from the device’s shelf life and two days of operation.&nbsp;<iframe id="655f42a06c848cd841ea922a" width="250" class="specs-iframe" height="440" src="https://wevolver.com/iframe/specs/digi-xbee-3-global-lte-m-nb-iot-development-kit?iframe=true" frameborder="0" scrolling="no" data-lf-form-tracking-inspected-kn9eq4roawkarlvp="true" data-lf-yt-playback-inspected-kn9eq4roawkarlvp="true" data-lf-vimeo-playback-inspected-kn9eq4roawkarlvp="true"></iframe>Maintaining high efficiency and small size both together is a &nbsp;challenging requirement. Increasing the frequency of operation reduces the size of passives while increasing losses, thereby reducing efficiency. The proliferation of portable IoT devices creates a need for multiple customized versions of voltage regulators, especially concerning output voltage and current specifications. Accordingly, an IoT device manufacturer may get forced to maintain a sizeable and costly inventory of different regulators and the passives required to support them.<h2 dir="ltr">A State-of-the-Art Solution for Powering Small IoT Products</h2>The ideal solution to power small IoT devices is a voltage regulator that addresses these shortcomings. Let’s take a look at <a href="https://www.mouser.com/new/maxim-integrated/maxim-max17220-max17225-converters/" target="_blank">Analog Devices MAX17222 nanoPower synchronous boost converter</a> and understand how a power converter contributes to energy and space-saving in small IoT devices.&nbsp;MAX17222 offers a 0.4V to 5.5V input range, a 0.5A peak inductor current limit, and an output voltage selectable using a single standard 1% resistor. A novel True Shutdown™ mode yields leakage currents in the nanoampere (nA) range, making this a genuinely nanoPower device! The essential elements of the MAX17222 concerning shutdown and quiescent currents are shown in Fig. 2 below.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjY2NjczNTEwNDM0LTE2NjY2NzM1MTA0MzQucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" class="fr-fic fr-dii">Fig. 2: MAX17222 shutdown and quiescent currents. Source: Analog DevicesThe True Shutdown feature disconnects the output from the input with no forward or reverse current, resulting in a very low leakage current. The reduction in shelf life we calculated for the specific solution is 1.8 months out of 3 years for a 100mAh cell. With 0.5nA leakage current, the shelf life for the same cell over three years gets reduced by only 3 hours!If a pull-up resistor is employed to enable/disable operation, the pull-up current in True Shutdown mode must also get accounted for. If the enable (EN) pin gets driven by a push-pull external driver powered by a different supply, then there is no pull-up current, and the shutdown current is only 0.5nA.<h3 dir="ltr" id="isPasted">The Quiescent Current Advantage</h3>The input quiescent current (IQINT) for MAX17222 is 0.5nA (Enable open after startup), and the output quiescent current (IQOUT) is 300nA as shown in fig. 3. The additional input current needed to feed the output current (I&gt;QOUT_IN) must be added to IQINT to calculate the total input quiescent current. Since the output power is related to the input power by the efficiency (POUT = PIN × η), it follows that:IQOUT_IN = IQOUT × (VOUT/VIN)/ηIf VIN = 1.5V, VOUT = 3V and efficiency η = 85%, we have:IQOUT_IN = 300nA × (3/1.5)/0.85 = 705.88nAOne adds the 705.88nA to the input current of 0.5nA yields a total input quiescent current of 706.38nA (IQINGT). This calculation is fourteen times better than the typical case previously discussed. With 0.7µA of quiescent current, the two days of reduced operation calculated for the specific solution becomes only three and a half hours.<iframe width="640" height="360" src="https://www.youtube.com/embed/-nhPd19evC8?&amp;wmode=opaque&amp;rel=0&amp;enablejsapi=1&amp;origin=https://www.wevolver.com" frameborder="0" allowfullscreen="" class="fr-draggable" data-lf-form-tracking-inspected-kn9eq4roawkarlvp="true" data-lf-yt-playback-inspected-kn9eq4roawkarlvp="true" data-lf-vimeo-playback-inspected-kn9eq4roawkarlvp="true"></iframe> <h3 dir="ltr" id="isPasted">Enable Transient Protection Mode</h3>The MAX17222 includes an option to Enable Transient Protection (ETP) mode. When activated by the presence of a pull-up resistor, extra on-chip circuitry powered by the output capacitor assures that EN stays high during short transient disturbances at the input. This feature is essential to prevent the device from shutting down unintentionally during short transients. When the device operates in ETP mode, the quiescent current calculated above increases by a few tens of nanoamps.<h3 dir="ltr">The RSEL&nbsp;Advantage</h3>The MAX17222 trades off the traditional resistor-divider used to set the output voltage value with a single output selection resistor (RSEL) (Fig. 3). The chip uses up to 200μA to read the RSEL value at startup. This occurs only during the select resistor detection time (typically 600µs), virtually eliminating the continuous contribution of RSEL to the quiescent current.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjY2NjczNzkzMDE3LTE2NjY2NzM3OTMwMTcucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" class="fr-fic fr-dii">Maxim Integrated (Analog Devices) MAX17220 - MAX17225 DC-DC Converters. Source:&nbsp;<a href="https://www.mouser.com/new/maxim-integrated/maxim-max17220-max17225-converters/" rel="noopener noreferrer" target="_blank">Mouser Electronics</a>A single standard 1% resistor sets one of the 33 different output voltages, separated by 100mV increments between 1.8V and 5V. The result is a slight reduction in the Bill Of Materials (BOM) (as the design has one less resistor compared to the conventionally used potential-divider circuit) and a lower quiescent current.<h3 dir="ltr">The Efficiency Advantage</h3>The MAX17222 features low RDSON, on-board powertrain Metal–Oxide–Semiconductor Field Effect Transistor (MOSFET) transistors to yield excellent efficiency even when operating at frequencies high enough to warrant a small overall PCB size. The low quiescent current design extends the outstanding efficiency performance down to a few microamps of load current. Fig. 4 shows the efficiency curves for the MAX17222 for varying load currents at different input voltages.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjY2NjczOTcwODczLTE2NjY2NzM5NzA4NzMucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" id="isPasted" class="fr-fic fr-dii">Fig. 4: MAX17222 efficiency curves, with VOUT = 3.3V at various values for VIN. Source: Analog Devices<h2 dir="ltr">Conclusion</h2>The IoT market has generated an explosion of small, wirelessly connected, battery-operated devices. These devices continue to lower the power loss boundaries for operation (efficiency) and shutdown (leakage current). As battery technologies continue to evolve and get better at holding charge, advancements in power electronics must go hand in hand to meet the growing needs of miniature IoT devices.&nbsp;For small IoT product development, engineers can use power converters such as Analog Devices <a href="https://www.mouser.com/new/maxim-integrated/maxim-max17220-max17225-converters/" target="_blank">MAX17222</a> ultra-low quiescent current, high-efficiency synchronous buck converter to significantly increases IoT devices’ shelf and operation life.This article is based on an<a href="https://www.mouser.com/ebooks/Power-Management-for-all-of-Tomorrows-Innovations" target="_blank">&nbsp;e-book</a> by Mouser and Analog Devices. It has been substantially edited by the Wevolver team and Electrical Engineer <a href="https://www.wevolver.com/profile/ravi.rao" target="_blank">Ravi Y Rao</a>. It's the final article from the Power Management for Tomorrow’s Innovations Series.<hr>The <a href="https://www.wevolver.com/article/power-management-for-tomorrows-innovations" target="_blank">introductory article</a>&nbsp;covered the fundamentals of power electronics, the technology behind highly-efficient power conversion in different electrical/electronic systems.&nbsp;The <a href="https://www.wevolver.com/article/finding-the-sweet-spot-for-flyback-converters-in-electric-vehicles/" target="_blank">first article</a> shares some design techniques for efficient power management in EVs. It covers how manufacturers can build significantly better vehicular electric power systems with systematic planning and innovative power electronic solutions.The <a href="https://www.wevolver.com/article/ultralow-noise-switching-power-supplies-for-reduced-electromagnetic-interference/" target="_blank">second article</a>&nbsp;introduced readers to silent switching and how it prevents EMI at the source, rather than adding shields and filters to the product later.&nbsp;The <a href="https://www.wevolver.com/article/current-sensing-with-digital-power-systems-managers" target="_blank">third article</a>&nbsp;describes current measurement techniques using LTC297x series components by Analog Devices. It presents some application circuits and compares different approaches for current sensing in power electronic converters.The <a href="https://www.wevolver.com/article/selecting-the-best-power-solution-for-radio-frequency-signal-chain-phase-noise-performance" target="_blank">fourth article</a>&nbsp;discussed the problems associated with phase noise and experimentally showcased how power supply designs can be optimized to deal with them.The <a href="https://www.wevolver.com/article/extending-the-battery-life-of-hearables-and-wearables-with-single-inductor-multiple-output-switching-architecture" target="_blank">fifth article</a>&nbsp;featured Single-Inductor Multiple-Output architecture that integrates different power supply functionalities to drastically reduce the overall size and costs for wearables.&nbsp;The <a href="https://www.wevolver.com/article/building-power-and-protection-circuits-for-vehicle-asset-tracking-devices" target="_blank">sixth article</a>&nbsp;describes how vehicular asset-tracking devices are powered with small, efficient power solutions and protected from electrical stresses.The <a href="https://www.wevolver.com/article/power-supply-subsystems-for-remote-patient-vital-sign-monitoring" target="_blank">seventh article</a>&nbsp;explains how designers can implement and validate proven power supply circuits for enabling the reliable operation of healthcare devices.The <a href="https://www.wevolver.com/article/nano-power-converters-for-extending-the-battery-life-of-small-iot-products" target="_blank">final article</a>&nbsp;dealt with a specific IoT power management solution for small, and portable gadgets. It showcases a nano-Power boost converter that ‘operates on fumes’ to make the most out of all the available energy.<hr><h2 dir="ltr">About the sponsor: Mouser Electronics</h2>Mouser Electronics is a worldwide leading authorized distributor of semiconductors and electronic components for over 1,100 manufacturer brands. They specialize in the rapid introduction of new products and technologies for design engineers and buyers. Their extensive product offering includes semiconductors, interconnects, passives, and electromechanical components.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjY2NjczOTcwNTk2LTE2NjY2NzM5NzA1OTYucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" width="720" height="91" id="isPasted" class="fr-fic fr-dii"><h2 dir="ltr">References</h2>[1] Make Your IoT Device Last Longer with a nanoPower Boost Converter Maxim Integrated (Analog Devices) and Mouser Electronics, [Online] , Available from:<a data-lf-fd-inspected-kn9eq4roawkarlvp="true" href="https://www.mouser.com/pdfDocs/ds37-make-your-iot-device-last-longer-with-a-nanopower-boost-converter.pdf" target="_blank">https://www.mouser.com/pdfDocs/ds37-make-your-iot-device-last-longer-with-a-nanopower-boost-converter.pdf</a>

Article #8 of Power Management for Tomorrow’s Innovations Series: Power electronics converters with an efficiency of up to 95% and very low quiescent current can make the Internet of Things devices last for months together.

Nano Power Converters for Extending the Battery Life of Small IoT products

Article #7 of Power Management for Tomorrow’s Innovations Series: Power supplies utilized in the medical industry must be compact, reliable, long-lasting, and robust.

Power Supply Subsystems for Remote Patient Vital Sign Monitoring

Flex Power Modules-Fri Jun 30 2023 23:59:59 GMT+0200 (Central European Summer Time)

Flex Power Modules-Mon Jul 31 2023 23:59:59 GMT+0300 (Eastern European Summer Time)

Flex Power Modules-Thu Aug 31 2023 23:59:59 GMT+0300 (Eastern European Summer Time)

Flex Power Modules-Thu Aug 31 2023 23:59:59 GMT+0200 (Central European Summer Time)

Flex Power Modules-Sat Sep 30 2023 23:59:59 GMT+0300 (Eastern European Summer Time)

Protolabs

Synopsys Inc

Nimbus Engineering Inc-Fri Jun 30 2023 23:59:59 GMT+0200 (Central European Summer Time)

Nimbus Engineering Inc-Mon Jul 31 2023 23:59:59 GMT+0300 (Eastern European Summer Time)

Nimbus Engineering Inc-Thu Aug 31 2023 23:59:59 GMT+0300 (Eastern European Summer Time)

Nimbus Engineering Inc-Thu Aug 31 2023 23:59:59 GMT+0200 (Central European Summer Time)

Nimbus Engineering Inc-Sat Sep 30 2023 23:59:59 GMT+0300 (Eastern European Summer Time)

power conversion

power conversion

Profiles