Inductors and Transformers

Inductors and Transformers
Automotive application
EPCOS (Shanghai) Ltd.

A Member of TDK-EPC Corporation
Shenzhen, China
Sep., 2014
Standard Inductors
Power
Transponder Chip Inductors CAN / FlexRay Bus
Coils Inductors shielded / Data Line Chokes
unshielded
Power Signal EMC

Signal Use Inductors
Inductors Filters
© [Legal Entity] 2014

[Presentation topic] • [Chapter title] A Member of TDK-EPC Corporation
[Department] • [04/14] • 2
Specific Designs Standardization (1)
Core Dimension Typical Typical

shape lxwxh Output Power Mounting Pictures Application Features
EMC behaviour
IC voltage
EP 6 8 x8 x7 3...5 Watt SMD High L - values
Park control
High frequencies
Gate drive Multi output
ER 11 12 x 12.5 x 6 3...5 Watt SMD
VFD display High AC ripple
ER 14 15.5 x 16 x 7 5…10 Watt SMD
LED High frequencies
Car alarm Multi output
E 13 18 x 14 x 12 5…10 Watt SMD EMC choke (high bias)
Start stop High turn ratios
E 16 22 x 17 x 12.5 5...20 Watt SMD Higher currents
Dashboard

[Department] • [04/14] • 3

Engine EMC choke (high bias)
Management Boost choke
EV 15 22 x 16 x 10.8 5...20 Watt SMD
VFD display Multi output
Higher currents / ratio
HID lamp High peak currents
EHP16 23 x 16 x 11 20...35 Watt SMD
LED lamp High power density
EHP19 25 x 20.5 x 12 35...50 Watt SMD
Fuel injection High frequences
EHP25 22.5 x 27 x 20 35...70 Watt PTH Fuel injection High frequencies
EHP26 27.5 x 27 x 21 70...100 Watt PTH Hybrid High I peak / low profile

[Department] • [04/14] • 4

DC/DC Low Rdc
converter
ERU 13 13 x 12 x 7.5 70Watt SMD High I sat
LED lamp
Flat design

[Department] • [04/14] • 5
Specific Designs Focus
• Customer specific designs are realized

Based on “black box specifications” from our customers
As modification of one of the standard designs
• Customer benefit
AECQ-200 qualified design
Optimized sampling times
Short approval time based on generic datas of family-qualification

[Department] • [04/14] • 6
Major Applications overview (1)
Dashboard: Airbag: SIMID Car radio/Video:
SIMID Power inductor SIMID
CAN bus choke CAN bus choke CAN bus choke
Cooling Fan:
Rod core choke
Fuel Injection:
Transformer/
Power inductor/
CAN bus choke
LED/HID: Power inductor Start-Stop module: EPS: SIMID/Ring core

EHP/EHR transformer/ ERU choke or Or Cylinder choke/
CAN bus choke Rod core choke CAN bus choke

[Department] • [04/14] • 7
Major Applications overview (2)
HVAC: BCM: SIMID/ TCU:

Transformer Power inductor/ Power inductor
CAN bus choke CAN bus choke
PDC: EP6
transformer
PEPS:
SIMID
Transponder
TPMS:SIMID Customized Immobilizer:

Transponder antennas Transponder

[Department] • [04/14] • 8
Major Applications overview — xEV
On Board Charger
DC/DC Converter
PFC choke
Current Sensor Resonance choke
Gate driver transformer Power Transformer
Power Transformer Output choke
Output choke Current sensor
Resonance choke ERU choke
Auxiliary transformer Auxiliary transformer
Inverter
Transformer

[Department] • [04/14] • 9
Signal Use Inductors
Standard SIMID Inductors
Major applications
Standard Inductors: • Automotive - Power train applications,

SIMID series (size convenience applications, safety
0603 to 2220) applications
• Information & Communications - DSL
applications, mobile applications, data
processing systems
• Consumer - e.g. Home appliances,
entertainment electronics
• Industrial - e.g. Power supply &
conversion, power quality solutions (e.g.
power meter)
[Department] • [04/14] • 11
Standard SIMID Inductors
Functions
SIMID series • Resonant circuits

(size 0603 to 0805) • Impedance matching
• RF Filtering
SIMID series • Filtering of supply voltages

(size 1210 to 2220) • Coupling
• Decoupling
• Storage chokes for small DC/DC converters
[Department] • [04/14] • 12
SIMID Product Range
0,001 0,1 SIMID 0402
= LR 0402 phase out B82499
1005 0,4 0,09
= IR
0603 0,001 0,22 SIMID 0603
1608 B82496
1,8 0,11
0805 0,0027 6,8 SIMID 0805

2012 B82498
1 0,08
1008 0,01 100 SIMID 1008

2520 phase out B82494
0,28 0,06
1210 0,01 10 SIMID 1210

3225 B82412
0,7 0,09
1210 0,0082 680 SIMID 1210

3225 B82422
2,05 0,06
1812 1 1000 SIMID 1812

4532 B82432
1,3 0,055
2220 1 10000 SIMID 2220

5650 B82442
3,51 0,025
Dimensions according EIA standard

[Department] • [04/14] • 13
TDK-EPC Transponder Coils Product Range
Chip coil X / Y- Transponder Coils Z Transponder Coil 3D-Transponder Coil
TC1210 8 mm length 11 mm length B82451L* B82453C*A*

1210 (EIA) (future generation) (under development)
B82450*A* 7.7 x 7.5 x 3.5 mm 11.5 x 12.5 x 3.6 mm
1.08 mH TPL802727*
11.4x3.5x2.4mm Ultrahigh sensitivity
7.8x2.7x2.7mm
1 … 18,52 mH 1 … 26 mH
TC1812
1812 (EIA) B82450A*E* TPL118*
2.2mH 7.8x2.7x2.7mm 11.8x3.5x2.7mm SOP: Q1/2015 SOP: Q2/2015
1 … 18,52mH
Passive Entry / Passive Start ( PEPS )
Tire Pressure Monitoring System (TPMS)
Immobilizer
[Department] • [04/14] • 14
Transponder coils TDK-EPC: application map
S (mV / µT)
80
PEPS TPMS
70
60
NEW 3D* 11mm
50
40
30 8mm
20
Z coil
10 TPMS TC1812 7mm*
TC1210
0
0,68 1 2,36 3,45 4,75 6,75 7 18,52
* under development L (mH)

[Department] • [04/14] • 15
X/Y Coil Market Leader: B82450A*
• Available in two Sizes:
8 mm B82450A*E* 7.8x7.8x2.7mm
− L values from 1mH up to 18.52 mH @ 125KHz
− Sensitivity (typ) up to 50mV/µT
11 mm B82450A*A* 11.4x3.5x2.7mm
− L values from 1mH up to 7.20 mH @ 125KHz
− Sensitivity (typ) up to 51mV/µT
• Temperature range: -40 °C to +125 °C
• Suitable for lead-free reflow soldering profiles acc. to JEDEC J-STD 020C
Optimized core geometry and

material:
• Higher sensitivity and coupling The molded structure provides
protection and contributes to
• Low inductance drift throughout the ruggedness of the part:
the temperature range
Withstands the 1000 x 1 m
(concrete floor) drop test
Welded Terminals for higher
Improved terminals construction
reliability
for mechanical stability

[Department] • [04/14] • 16
New 3D coil B82453C* 3.6mm height
Target Specification Moulded coil

68-72mV/µT @ 125KHz example • Very high mechanical robustness
• Maximum wire protection
Item name B82453C*A* typical dimensions
11.5 × 12.5 × 3.5 mm (3.6max)
& size
Small overall geometry
Lxy: 6.75mH ±5% at 125kHz • Area of only 144mm² saves 20% space
Lz: 12mH±5% at 125kHz on PCB in comparison to discrete
Electrical Q(xyz@125KHz): 35 typ solutions
Characteristics DCR(x,y,z): 93, 94, 156Ω typ
SRF(x,y): >500 kHz Optimal terminal construction 3 axis in one component
SRF z: > 400KHz
S typ(x,y,z): 68-72mV/µT • High meniscus area (better AOI) • Saves mounting and testing time
(@125KHz in three axies) • High mechanical stability • Better “dynamic” performance
• Pad layout compatible with standard • Reduced complexity in component
coils on the market handling
Temperature -40 to +85 °C
range
Laser welding wire connection Optimized core geometry and
AEC-Q200 compliant
material
Heat shock test • Wire connection with high reliability
Reliability –40 to +105 °C • More than 10 times Reflow to fail tested
• Large ferrite core and new material
Humidity test assures higher sensitivity in all axis
85°C 85% RH • Core geometry optimizes
High resistance wire class
communication in 45° angles.
Mechanical Drop test (50g test fixture on A200 • Improved thermal performance, Tcurie
Strength concrete): 1000 drops x 1m; • High-temperature resistance at reflow >150°C and high stability over the
random orientation. • Laser wire stripping used temperature range (<±3%)
(TBC)

[Department] • [04/14] • 17
New 3D coil standard B82453 C*: dimensions

[Department] • [04/14] • 18
New 3D coil standard B82453C*
7 6
8 5
Botton view
1 4
2 3
5 X 1
4 Y 8
3 Z 7

[Department] • [04/14] • 19
New 3D coil: Project schedule (6.75mH)
2014 2015
March – April May-June July-August Sept-October Nov-December Q1 Q2 Q3
CW18 CW27 CW35 CW44 CW52 CW13 CW26 CW39
B82453C 3.6mm height
A-samples B-samples C-samples,

SOP May 2015
CW44 CW50 CW10-2015
Pilot line , samples capability
Production line implementantion and set up
AEC-Q200 Qualification

[Department] • [04/14] • 20
Power Inductors

[Department] • [04/14] • 21
High temperature SMT Power Inductors – Ex-EPCOS
Basic Features
P-series, R-series, D-series, M-series
Automotive
Up to 150°C, AEC-Q200 qualified
• Shielded construction (P-series)

• New: High saturation current capability (R-series)
• Unshielded construction (M-series)
• Coupled inductor (SEPIC choke)

[Department] • [04/14] • 22
Power Inductors Portfolio (1)
Size (L x W) Height Inductance Rated Current Saturation
Series Shielded
in mm in mm in µH in A Current in A
B82472 P6 7.3 x 7.3 4.5 Yes 1 … 1000 0.20 ... 3.60 0.15 … 3.30
B82464 P4 10.4 x 10.4 4.8 Yes 0.82 …1000 0.34 ... 7.50 0.35 … 10.50
B82477 P2 12.5 x 12.5 8.5 Yes 1 …1000 0.65 … 11.00 0.80 … 25.00
B82477 P4 12.5 x 12.5 8.5 Yes 0.82 …1000 0.60 … 11.00 0.65 … 15.00
B82477 R4 12.5 x 12.5 8.5 Yes 0.82 …1000 0.65 … 11.00 0.80 … 25.00
B82473 M1 8.3 x 7.5 5.5 No 10 … 470 0.34 ... 2.30 0.40 … 2.50
B82475 M1 10.4 x 10.0 5.8 No 10 … 680 0.28 ... 2.60 0.30 … 2.75
B82477 D4 12.5 x 12.5 8.5 Yes 10 … 100 0.96 … 2.70

[Department] • [04/14] • 23
Portfolio (2) — New R-Series
Higher saturation current handling capability
Same geometry as standard power inductor: 12.5x12.5x8.5 (mm)
Samples available
AECQ200 qualification completed in Q2/2011
Suitable for Automotive LED Applications, Micro inverter (solar) ….
LR ToleranfL IR Isat Rmax Ordering code

ce
µH 20% = M MHz A A mΩ
0.82 0.1 11.5 27 5.0 B82477R4821M
1.50 9.75 20 6.5 B82477R4152M
2.00 8.90 18 8.0 B82477R4202M
3.00 8.25 15.5 9.0 B82477R4302M
3.60 8.05 13 10 B82477R4362M
4.70 7.50 12.2 11 B82477R4472M
5.60 7.25 11 11.5 B82477R4562M
6.80 6.60 10.5 15 B82477R4682M
10 5.90 8.75 18.5 B82477R4103M +37%*
15 5.00 7.25 25 B82477R4153M
22 4.20 6.10 32 B82477R4223M
33 3.38 5.20 50 B82477R4333M
47 3.20 4.30 60 B82477R4473M +43%*
68 2.65 3.55 85 B82477R4683M
100 2.25 2.90 120 B82477R4104M +49%*
150 1,80 2.40 175 B82477R4154M
220 1.35 2.00 290 B82477R4224M
330 1.12 1.70 425 B82477R4334M
470 1.02 1.35 605 B82477R4474M
680 0.80 1.10 860 B82477R4684M * vs. B82477P4
1000 0.65 0.95 1350 B82477R4105M

[Department] • [04/14] • 24
Signal EMC Filters
CAN Bus Chokes Portfolio (1)
Type Size ( in mm ) Customer Benefit Status

B82790-xxx 9 x 6 x 5.2 ring-core , encapsulated since 1995 series
B82793-xxx 9 x 6 x 4.8 ring-core , reduced height since 1998 series

cost optimized
B82799-xxx EIA 1812 R2.5 ring-core , reduced size since 2000 series
4.5 x 3.2 x 3.2 -75 % space
up to 150 °C operating temperature
B82789-...N* EIA 1812 I-core I-core , reduced size since 2001 series
4.5 x 3.2 x 3.2 - 75 % space
cost optimized
B82789-...H* EIA 1812 I-core high temperature version (150 °C) new series 2004
4.5 x 3.2 x 3.2

[Department] • [04/14] • 26
CAN Bus Chokes Portfolio (2)
Capacity Expansion
ACT45B
Recommendati
Bifilar
on for new
designs
SIMDAD
I core types
Change from ACT4532 to

Sector
SIMDAD
Phase out …
ACT4532
B82793
Change from ZJYS to B82793

Ring core types
Recommendation for
new designs
ZJYS

[Department] • [04/14] • 27
Portfolio (3) — ACT45B Heidenheim (code: B82787 series)
ACT45B: TDK CAN bus chokes in size EIA 1812
First ACT45B line installed in Heidenheim in Dec 2010
capacity expansion
for ACT45B customers in Europe
Two types (top seller values): 51 µH and 100 µH
AEC-Q200 qualification successfully completed

Series production since end of May 2011
Strategy: Serve European ACT45B customers out of

European production
Relax SIMDAD delivery situation by switching certain projects
to ACT45B Hdm
Sales channel: EPCOS

[Department] • [04/14] • 28
Main Applications
Application USS
Explanation (1)
System Description Sensors/Transformers
Optical and/or accustical signal which 4 rear
Parking aid system
announces distances from 250 to 25cm or 8 front + rear
"Hands-free" automatically parking
Parking assistance system xxxx10 ( 6 front, 4 rear )
maneuvers ( in combination with EPS )
Identification of vehicles located in the
Side View Assist xxxx14 ( 8 front, 6 rear )
blind spot of the driver
(source : bosch)

[Department] • [04/14] • 30
Application USS
Products
Ringcore 7
Features
• Iron powder core
• Potted
• SMD
• 11mm x 13,3mm x 6,5mm
• Operating temp. -40°C to +85°C
EP 6
Features
• Ferrite Core
• Non Potted
• SMD
• 9mm x 7,9mm x 7,6mm
• Operating temp. -40°C to +85°C
[Department] • [04/14] • 31
Application LED
Explanation (1)
Application example 1 Application example 2
Car battery Car battery
T4202
Transformer
T6969 signaling
T6968
Transformer Transformer T4202

PI Transformer
cornering light
To high and To high and PI

To signaling
low beam low beam
light xxx

[Department] • [04/14] • 32
Application LED
Explanation (2)
Multi Functional Control Unit:

Application: Low and High Beam
Circuit topology: Flyback or Buck- and Boost converters
Number of components: Flyback design includes one transformer per control unit
Buck/Boost design includes 3 to 5 Power Inductors per
control unit
Number of control units: One per headlamp
Signal Power Converter Board :

Application: Daytime running light, signal light and cornering light
Circuit topology: Flyback converters
Number of components: One Transformer and one Power Inductor
Number of power conv.: One or three power converter PCBs per car

[Department] • [04/14] • 33
Application LED (HID)
Products
EHR Series
Features
• Transformer or Storage Choke for power-supply
• 12 Vdc : 5…250 Vdc
• Increased reflow capability leadfree
• AOI optimized design
• Possible cooling on top surface
• Material class -40…155°C

[Department] • [04/14] • 34
Application Piezo Fuel Injection
Explanation
12 250 V
V 43 A
Transfer Piezo
DC/DC
(Boost) Stack
transformer
choke
(source : bosch)

[Department] • [04/14] • 35
Application Piezo Fuel Injection
Products
EHR Series
Features
• Transformer or Storage Choke for power-supply
• 12 Vdc : 5…250 Vdc
• Increased reflow capability leadfree
• AOI optimized design
• Possible cooling on top surface
• Material class -40…155°C

[Department] • [04/14] • 36
Application EPS (Electric Power Steering)
explanation (1)
EPS is a system for reducing the
steering effort on cars by using E-motors
to assist in turning the wheels.
Running systems:
•Electric Power Steering (EPS) with
with only E-motor (also EAS, EPAS)
•Electro Hydraulic Power Steering (EHPS) with

electric motor driving a hydraulic pump

[Department] • [04/14] • 37
Application EPS
explanation (2)
The EPS electronic control unit (ECU) calculates the assisting power
needed, in accordance with the driver’s steering operation
and the vehicle’s speed
•EHPS: E-motor is running continuosly
•EPS: the E-motor gives the assisting power on demand only
Advantages of EPS systems:

•Better driving dynamic
•Higher comfort (e.g. parking)
•Higher safety
•Reduction of fuel consumption by 0,4l/100km
•Reduction of CO2 emission

[Department] • [04/14] • 38
Application EPS
Products (1)
• DM choke:
Chokes for EMI suppression
• Attenuation of Differential Mode

(assymmetrical) interferences
• CM choke :
Typ. 2-4 µH / 25-40 A (125A peak)
at 140 °C, max 180°C
• Attenuation of Common Mode
(symmetrical) interferences
Typ. 15-250µH / 10-20A (70A peak)
at 140°C •Combined CMDM choke:

[Department] • [04/14] • 39
Application EPS
Products (2)
Cylindrical Core Chokes
Focus :
• wire diameter Ø 1.5 mm – 4 mm
• core diameter Ø min. 6 mm
Which leads to :
• inductance range 0.5 µH – 10 µH
• current 5 A – 25 A (max. 70 A)
• T max = 150 °C (component-temperature)

[Department] • [04/14] • 40
Key Technologies and Products in Automotive
EM EMobility Platform (1)
PCEM PowerChokes PT EM PowerTransformer
ER47 up to ERU65 cores Power range scalable from 1,8kW up to 3,0kW

Planar coils with different numbers of turns Winding primary wire wound , secondary planar
Standardized concepts for mounting, cooling and
connection to bus-bar
• Basic Isolation acc. IEC60664, Operating Temperature: -40°

°C to
EM series +150°
°C
[Department] • [04/14] • 41
xEV Typical Topology Boardnet Converter
Zero Voltage Switching
Phase Shift topology

[Department] • [04/14] • 42
xEV Typical Topology Onboard Charger
Boost PFC Full bridge Full wave rectifier
Interleaved 2-phase phase shift ZVS
250 V
1-phase …
power
network 430 V
PFC-choke Resonant choke Power transformer Output choke

fswitch = 100 kHz fswitch = 100 kHz fswitch = 100 kHz fswitch = 100 kHz
L = 50 µH … 150 µH L = 2… 5 µH P = 3.3 kW L = 100 µH
Irms = 9 A Irms = 16 A Turns ratio = 1.4 Ipeak = 16 A
Ipeak = 17 A Reinforced insulation

[Department] • [04/14] • 43
www.global.tdk.com • www.epcos.com

Inductors and Transformers

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Inductors and Transformers

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Inductors and Transformers

EPCOS (Shanghai) Ltd.

Power Signal EMC

© [Legal Entity] 2014

Core Dimension Typical Typical

© [Legal Entity] 2014

Core Dimension Typical Typical

EHP25 22.5 x 27 x 20 35...70 Watt PTH Fuel injection High frequencies

© [Legal Entity] 2014

Core Dimension Typical Typical

© [Legal Entity] 2014

• Customer specific designs are realized

© [Legal Entity] 2014

LED/HID: Power inductor Start-Stop module: EPS: SIMID/Ring core

© [Legal Entity] 2014

HVAC: BCM: SIMID/ TCU:

TPMS:SIMID Customized Immobilizer:

© [Legal Entity] 2014

© [Legal Entity] 2014

Standard Inductors: • Automotive - Power train applications,

SIMID series • Resonant circuits

SIMID series • Filtering of supply voltages

0805 0,0027 6,8 SIMID 0805

1008 0,01 100 SIMID 1008

1210 0,01 10 SIMID 1210

1210 0,0082 680 SIMID 1210

1812 1 1000 SIMID 1812

2220 1 10000 SIMID 2220

Dimensions according EIA standard

Chip coil X / Y- Transponder Coils Z Transponder Coil 3D-Transponder Coil

TC1210 8 mm length 11 mm length B82451L* B82453C*A*

Passive Entry / Passive Start ( PEPS )

Tire Pressure Monitoring System (TPMS)

* under development L (mH)

© [Legal Entity] 2014

Optimized core geometry and

© [Legal Entity] 2014

Target Specification Moulded coil

© [Legal Entity] 2014

© [Legal Entity] 2014

© [Legal Entity] 2014

March – April May-June July-August Sept-October Nov-December Q1 Q2 Q3

CW18 CW27 CW35 CW44 CW52 CW13 CW26 CW39

B82453C 3.6mm height

A-samples B-samples C-samples,

Pilot line , samples capability

Production line implementantion and set up

© [Legal Entity] 2014

© [Legal Entity] 2014

P-series, R-series, D-series, M-series

• Shielded construction (P-series)

© [Legal Entity] 2014

B82477 D4 12.5 x 12.5 8.5 Yes 10 … 100 0.96 … 2.70

© [Legal Entity] 2014

LR ToleranfL IR Isat Rmax Ordering code

© [Legal Entity] 2014

Type Size ( in mm ) Customer Benefit Status

B82793-xxx 9 x 6 x 4.8 ring-core , reduced height since 1998 series

© [Legal Entity] 2014

Change from ACT4532 to

Change from ZJYS to B82793

© [Legal Entity] 2014

AEC-Q200 qualification successfully completed

Strategy: Serve European ACT45B customers out of

TC1210 8 mm length 11 mm length B82451L* B82453CA