Vicor Corporation · NASDAQ:VICR
Vicor — WCX SAE World Congress Experience 2023
21 slides from Vicor's conference presentation, Apr 18, 2023
Slide 1: WCX SAE International April 18-20, 2023 Detroit
SE INTERNATIONAL» _—— APRIL 18-20;2023 DETROIT
Slide 2: Reducing range anxiety by reducing harness weight using power modules
Reducing range anxiety by reducing harness weight using power modules Nicolas Richard – Director Automotive Europe Vicor Corporation
Slide 3: The challenge: Wire harness weight and inefficiency underestimated
The challenge: Wire harness weight and inefficiency underestimated The wire harness is one of the three heaviest subsystems in today’s vehicles • 2,000 copper wires totaling 1 mile in length • 150lbs in highly contented vehicles “We didn’t know that our wiring harness for Mach-E was 1.6 kilometer lo
Slide 4: BMW 7 series G12 – complexity of wiring routing
BMW 7 series G12 – complexity of wiring routing • 12V power harness length: 5m • 12V power net : 27mm2 or 4AWG • Several 1kW loads in engine compartment • 12V @ 80A
Slide 5: Power delivery on typical 12V architecture
Power delivery on typical 12V architecture 40.44W 950W load Power harness 5m (16ft) length 79A rating 4AWG – 2kg (4.1lbs) Benefits: Drawbacks: • Known power architecture • Weight • Easy implementation • Routing complexity, high current connection and fuse • Wire commodity cost uncertain • Wire harne
Slide 6: Power delivery with 48V architecture: 85% weight reduction
Power delivery with 48V architecture: 85% weight reduction! 5.78W 950W load Power harness 5m (16ft) length 19A rating 10AWG – 0.24kg (0.48lbs) Benefits: Drawbacks: • 85% weight wire harness • New vehicle power delivery weight over 12V system architecture • Easier wire harness • Li-Ion Battery comple
Slide 7: 48V power wiring harness system design advantage
48V power wiring harness system design advantage Power Dissipation and Weight: Example: all wires ≥30A @ 12V show a potential of reducing: • Power dissipation by 5W to 10W • Weight by approximately 2,5 kg Assumptions: • 20 of 130 power supply lines ≥30A • with cross sections from 2,5mm2 to The trans
Slide 8: Doing things differently with the right technology?
Doing things differently with the right technology? The right technology is needed to enable an increase of the overall system efficiency with optimized Power Delivery Network while beneficiating wire harness weight reduction.
Slide 9: Enabling technology to bridge the voltages
Enabling technology to bridge the voltages SAC (Sine Amplitude Converter) topology and innovative controller designs and systems
Slide 10: Sine amplitude converter – what is it?
Sine amplitude converter – what is it? • Sine Amplitude Converter topology: • Zero Voltage Switching • Zero Current Switching • Fixed Ratio Conversion : • Divide/Multiply the Voltage/Current • Extremely fast transient current capability • Ideal transformer behavior K factor 1/16 1/4 1/1 4/1 • No ind
Slide 11: Fixed ratio converter - fast transient response
Fixed ratio converter - fast transient response • High frequency switching • Smaller magnetic components Low impedance path • Smaller path lengths for turns • Package has very low parasitic inductance on input/output connections • Response is flat as a function of ROUT from DC to over a MHz Vin Vout
Slide 12: Scalability of the vehicle Power Delivery Network across the range ICE/BEV
Fast transient response, low impedance and bidirectional operation enables Battery Virtualization Virtualize a 48V battery to enable Virtualize a 48V Battery to enable 48V load compatibility on a 12V vehicle 48V loads in a BEV with isolated SAC architecture Scalability of the vehicle Power Delivery
Slide 13: Product solution: NBM2317 and NBM3523
Product solution : NBM2317 and NBM3523 • Input/output range: 38V - 60VDC / 9.5V – 15VDC • Output current (step down): 80A – 1kW • Fixed ratio (k=1/4) • Peak efficiency: 98.3% 23mm x 17mm Weigh: 8.7g • Full power bidirectional • Input/output range: 38V - 60VDC / 9.5V - 15VDC • Output Current (step do
Slide 14: SAC technology with 12V architecture: 85% weight reduction
SAC technology with 12V architecture: 85% weight reduction SAC SAC 950W load Power harness length 5m (16ft) 79A rating 10AWG – 0.24kg (0.48lbs) Benefits: Drawbacks: • Minimum architecture • Not taking full change advantage of higher bus • Wire harness routing voltage at the load • 85% wire weight re
Slide 15: SAC enabling 48V battery virtualization: 85% weight reduction and efficiency
SAC enabling 48V battery virtualization: 85% weight reduction and efficiency SAC 950W load Power harness length 5m (16ft) 19A rating 10AWG – 0.24kg (0.48lbs) Benefits: Drawbacks: • PDN optimization • 48V load • Overall system weight reduction • Cost • Scalability • System power loss minimized
Slide 16: Enabling up to 85% wire harness weight reduction on a BEV architecture
Enabling up to 85% wire harness weight reduction on a BEV architecture Standard BEV architecture DC-DC 5m (16ft) power harness length 3AWG – 4kg Optimized BEV architecture SAC + regulation SAC 5m (16ft) power harness length 10AWG – 240g
Slide 17: Consolidation of power supply systems in a distributed 48V
Enabling weight reduction on a BEV architecture… further Consolidation of power supply systems in a distributed 48V: • 12V wiring harness reduced to a minimum • Leverage 48V and HV for high power loads and power distribution • Fewer LV battery storage (12V / 48V)
Slide 18: Additional application possibilities
Additional application possibilities Enable 48V load compatibility on a Commercial vehicle applications 12V vehicle power architecture (15 – 20 meters wire harness) (ICE for instance with 48V active suspension)
Slide 19: Conclusion – what can Vicor technology enable
Conclusion – what can Vicor technology enable • Increase the bus voltage to 48V enables up to 85% weight reduction on the power distribution wiring harness. • Better thermal management and wiring harness routing. • Reduction of system complexity and overall cost. • Increase electrical efficiency fro
Slide 20: Thank you
Nicolas Richard - author Thank you Nicolas Richard – Vicor Corporation Nicolas Richard is Vicor’s Director for Automotive Sales and Field Application Engineering in Europe. Nicolas has 19 years of automotive experience in Infotainment, ADAS, Power electronics systems (DC/DC, Inverter, BMS) and semic
Slide 21: References
References • BMW AG – Ottmar Sirch : Future vehicle Power supply with 48V Nov 2019.