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In an era where energy efficiency and sustainability are essential, Battery Management Systems (BMS) have emerged as critical components in both industrial and automotive applications. These systems play a vital role in monitoring, controlling, and optimizing battery performance, ensuring safety, longevity, and reliability. As the demand for electric vehicles (EVs) and renewable energy storage solutions continues to rise, the relevance of robust BMS technology cannot be overstated. In the automotive sector, BMS not only enhances vehicle performance but also contributes to the overall safety and efficiency of electric drivetrains. Similarly, in industrial applications, effective battery management is essential for maximizing uptime and operational efficiency in energy storage systems. Panasonic's portfolio of passive components for BMS is designed to meet these growing demands, providing innovative solutions that support the advancement of battery technology across various industries.
As the complexity of Battery Management Systems (BMS) increases, several technical challenges emerge that must be addressed to ensure optimal performance and reliability. One significant challenge is durability in harsh environments, including extreme temperatures, high humidity and different vibration profiles. This is particularly critical in automotive applications, in which components are exposed to this kind of conditions over extended periods.
Another pressing challenge is the need for miniaturization and weight reduction. As electric vehicles and industrial systems strive for greater efficiency, a growing demand for compact and lightweight components that do not compromise on performance is observed. This trend is essential for enhancing energy density and overall system efficiency, making it crucial for manufacturers to innovate continuously.
To tackle these challenges, Panasonic's range of capacitors, resistors, and inductors is designed with advanced materials and technologies that enhance durability and performance while supporting miniaturization. In the following sections, we will explore how these passive components contribute to overcoming the technical hurdles faced in the development of effective and reliable BMS solutions.
In the ecosystem of Battery Management Systems (BMS) for industrial and automotive applications, the importance of precision and reliability cannot be overstated. Among the key components that facilitate these attributes are resistors, particularly thin and thick film resistors. Panasonic has developed a comprehensive range of these technologies, each designed to meet the specific demands of high-performance battery management systems.
Thin film resistors play an essential role in voltage measurement and control within battery management systems. These resistors are typically used in series configurations, allowing them to withstand the high voltages that may occur during operation. The ability to measure and control voltage accurately is crucial, especially in environments where overvoltage conditions can arise. While Panasonic offers thin film resistors that can handle higher voltage ranges, it is essential to clarify that these are not classified as "high voltage" components in the traditional sense. Instead, they are designed for higher voltage applications, emphasizing precision rather than extreme voltage tolerance. An additional consideration is that ERA*V/K/P types feature an absorbable layer, which helps them withstand more temperature cycles. This characteristic can also be beneficial, as it may enhance their durability and reliability in demanding thermal environments. This distinction is vital for engineers who require components that provide accurate readings without compromising on performance.
In addition to thin film resistors, Panasonic also provides a variety of thick film resistor technology. Panasonic thick film resistors are engineered to handle significant thermal and electrical stresses, making them suitable for demanding applications. One of the standout features of Panasonic's thick film resistors is the integrated soft termination, which is automatically included in components sized from 0201 and larger.
The soft termination technology is a game-changer in the market. It allows the resistor to expand and contract with temperature fluctuations, thereby mitigating the risk of solder joint failure. In battery management systems, in which components are subjected to varying temperatures and currents, without soft termination, solder joints can become brittle and fail, leading to potential system malfunctions.
Part of Panasonic thick film resistors is high temperature technology, capable of withstanding maximum temperatures of up to 175°C. This capability is crucial for Battery Management Systems that may experience elevated temperatures due to high current loads. The concept of derating—with which the power capability of a resistor is reduced instead of 70° C at higher temperature of 105° C—becomes less of a concern and is particularly beneficial with high temperature resistor technology.
For instance, in a typical battery management scenario, temperatures can reach between 110°C to 125°C. Panasonic's thick film resistors allow for less power derating compared to standard components, ensuring that they can handle larger currents without compromising performance. This robustness makes them ideal for applications where reliability and durability are of vital necessity.
In summary, Panasonic's offerings of thin and thick film resistors are integral to the functionality and reliability of Battery Management Systems in industrial and automotive contexts. The precision of thin film resistors, combined with the robustness and thermal resilience of thick film resistors, ensures that these components can meet the rigorous demands of modern battery technologies. As the industry continues to evolve, the role of these passive components will remain crucial in supporting the performance and safety of battery management systems.
Panasonic offers inductors, specifically designed to monitor and control battery status, ensuring optimal performance and safety in these advanced systems.
Inductors play a critical role in regulating and controlling current flow within battery management systems. This regulation is essential for both charging and discharging processes of the battery. By smoothing out fluctuations in current, inductors help maintain stable operation, which is vital for the longevity and efficiency of the battery. This capability is particularly important in applications where rapid changes in current demand can occur, such as during acceleration or regenerative braking in electric vehicles.
Another significant function of inductors in BMS is their ability to suppress electromagnetic interference (EMI) and ensure compliance with electromagnetic compatibility (EMC) standards. As electric vehicles incorporate various electronic components, managing EMI becomes crucial to prevent disruptions in performance and maintain the integrity of sensitive electronic systems. Panasonic's inductors are designed to minimize differential mode noise, thereby enhancing the overall reliability and safety of the battery management system.
Inductors also contribute to the safety of Battery Management Systems by protecting against overcharging, deep discharging, and other potential hazards. By controlling the current flow - and at the same time withstanding high currentsinductors are acting as a buffer in the circuit and help prevent conditions that could lead to battery damage or failure. This safety feature is paramount in automotive applications, where the consequences of battery failure can be severe.
One of the standout offerings from Panasonic is the Power Choke Coils, which are surface mount power inductors known for their high heat resistance and exceptional DC bias characteristics. These metal composite inductors utilize a Hi-BS ferrous alloy magnetic material, ensuring reliability even in high-temperature environments.
Additionally, they exhibit a high tolerance for vibration or high ripple current capability, depending on the series, making them suitable for the demanding conditions often encountered in automotive applications.
These Power Choke Coils are extremely efficient, featuring low DC resistance (DCR) and, depending on the specific series, reduced eddy current losses. This efficiency not only enhances the performance of the power circuit but also simplifies the thermal design process, contributing to a more compact and effective battery management system.
Miniaturization of ECU power circuits: With their small case size and high current capability, Panasonic's inductors facilitate the miniaturization of electronic control unit (ECU) power circuits, allowing for more compact designs without sacrificing performance.
Low loss characteristics: The low loss characteristics of these inductors enable high efficiency in the power circuits of ECUs, which is essential for optimizing battery usage and extending the range of electric vehicles.
High reliability in severe conditions: The metal composite monolithic structure of Panasonic's inductors ensures high reliability, making them suitable for applications in harsh environmental conditions. Panasonic Industry offers anti-vibration power inductor components capable to withstand up to 30G and 50G.
In conclusion, especially Panasonic's inductors can play a vital role in the functionality and safety of Battery Management Systems for electric and hybrid vehicles. As the automotive industry continues to evolve, the significance of high-quality passive components like Panasonic's inductors will only grow, supporting the transition to more efficient and sustainable electric mobility solutions.
Panasonic's hybrid capacitors emerge is a vital component for BMS, combining the advantages of aluminum electrolytic and polymer capacitors. The essential advantage are their low leakage currents despite having high ripple current capability.
These hybrid capacitors are engineered to meet the demanding requirements especially of electric vehicles (EVs) and hybrid electric vehicles (HEVs), ensuring optimal performance, reliability, and safety.
Panasonic's hybrid capacitors are designed to deliver exceptional performance in various applications, particularly in battery management systems. Their key features include:
In summary, Panasonic's hybrid capacitors are a critical component in the functionality and reliability of Battery Management Systems and battery distribution units. In many aspects and specifications, these capacitors meet the demanding challenges of the “electrification of everything” – and the role of high-quality hybrid capacitors will remain essential in supporting the performance, safety, and efficiency of battery systems.
As vehicles become smarter and more electrified, the Vehicle Control Unit (VCU) has emerged as a critical component in managing and optimizing their performance. But what exactly is a VCU, and why is it so essential in today’s automotive systems?
A Vehicle Control Unit (VCU) is the brain behind many of a vehicle’s core functions. It acts as a centralized controller that processes signals from various sensors and other Electronic Control Units (ECUs), then issues commands to components such as motors, brakes, steering systems, and more.
In modern vehicles, especially those with advanced driver-assistance systems (ADAS) or electric drivetrains, the VCU plays a pivotal role in coordinating power devices, body electronics, and drive systems. It ensures that all subsystems operate harmoniously based on real-time data inputs.
(Fig. 1 Role of the VCU)
With the automotive industry moving toward Level 3 autonomous driving and beyond, the demand for high-performance VCUs is rapidly increasing. As more vehicle functions become electrified and automated, the need for centralized control grows. This shift brings challenges such as:
To meet these demands, VCUs must be built with components that are compact, energy-efficient, high-frequency capable, and highly reliable.
A typical VCU includes the following key components:
These components work together to interpret sensor data and issue precise control signals to various vehicle systems.
(Fig. 2 Overall configuration of the VCU)
Used to convert battery voltage to levels required by other components. Key parts include:
(Fig. 3 Components used in the DC/DC converter)
Handles communication with external devices. To protect against electrostatic discharge (ESD), it includes:
(Fig. 4 Components used in the transceiver IF)
Controls voltage switching for actuators. To manage noise and ensure stable operation, it uses:
(Fig. 5 Components used in the motor drive circuit)
As VCUs become more complex, the components used must meet stringent requirements:
| Feature | Importance in VCU Design |
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| Miniaturization | Saves space in compact ECUs |
| High Frequency | Supports fast switching and communication |
| High Precision | Enables accurate control and measurement |
| Low Loss | Improves energy efficiency |
| Large Current Handling | Supports high-power applications |
| ESD Protection | Ensures communication reliability |
Panasonic Industry offers a wide range of components tailored for VCU applications, including capacitors, inductors, resistors, and ESD protection devices.
The VCU is a cornerstone of modern vehicle architecture, especially as we move toward more autonomous and electrified mobility. Its ability to manage complex systems in real time depends heavily on the quality and performance of its internal components. By choosing the right parts, engineers can design VCUs that are not only powerful and efficient but also compact and reliable.
| Component | Feature | Large Current | Low Loss | Miniturization (small size) | High Frequency | High Precision | |
| Conductive polymer hybrid aluminum electrolytic capacitor | Low ESR High reliability |
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| Power Inductors for Automotive application | Large current, low loss High reliability |
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| High precision, high resistance to heat |
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| Chip varistor |
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| ESD suppressor |
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The automotive industry is in the middle of a seismic shift. With the rise of autonomous driving and electrification (the "CASE" era), core vehicle systems are being completely re-imagined. One of the most critical evolutions is happening in the steering system.
As we move towards higher levels of vehicle autonomy, the demands placed on Electric Power Steering (EPS) systems are exploding. Engineers are now tasked with designing circuits that are not only more powerful and efficient but also meet unprecedented standards for safety and reliability. How do you design an EPS that can handle the complex demands of by-wire technology and functional safety while minimizing power loss and physical footprint?
This article provides a technical deep-dive into the modern EPS, breaking down its architecture, the technological forces shaping its evolution, and the critical electronic components that form its backbone.
At its core, an Electric Power steering (EPS) is a system that uses an electric motor to assist the driver, reducing the effort needed to turn the steering wheel. Unlike traditional hydraulic systems that constantly draw power from the engine, an EPS is far more efficient, only consuming energy when steering assistance is required. This directly contributes to better fuel economy and is a key enabler for electric vehicles (EVs).
(Figure1: Operation of the EPS)
The EPS is evolving rapidly due to two major trends:
Electrification: Modern vehicles rely on battery power. Electrifying components like the steering system simplifies the overall mechanism and improves energy efficiency. For autonomous driving, where the vehicle's computer needs total control, full electrification is essential.
By-Wire Connection: The future of steering is "by-wire". This means the mechanical link between the steering wheel and the axle is replaced by an electrical connection. This separation allows for more precise, computer-controlled steering adjustments, a fundamental requirement for autonomous navigation. As the driver's role diminishes at higher autonomy levels, the vehicle assumes primary control, making by-wire systems indispensable.
(Figure:2 Configuration change resulting from by-wire connection)
With greater autonomy comes greater responsibility. In a by-wire system, failure is not an option. To ensure maximum safety and reliability, modern EPS designs incorporate a redundant structure. This often means building the motor-driving inverter with a dual-circuit design. If one circuit fails, a backup immediately takes over, ensuring the system remains operational.
However, this raises a new engineering challenge: redundant circuits, along with the need for more powerful motors in advanced systems, increase power consumption. This dilemma forces engineers to seek out electronic components that deliver on four key properties: low loss, high heat resistance, high precision, and small size.
(Figure3: Configuration changes resulting from the adoption of a redundant structure)
Let's break down the key functional blocks within a typical EPS electronic control unit (ECU):
Noise Filter: Suppresses electromagnetic interference (EMI), both internal and external, to prevent system malfunctions.
Voltage Conversion Circuit (Inverter): Converts the vehicle's DC voltage to power the motor, typically using Field-Effect Transistors (FETs) for high-frequency switching. It also monitors the temperature of these critical components.
Gate Drive Circuit: Precisely controls the switching of the FETs in the inverter.
DC/DC Converter: Steps down voltage to supply stable power to the main control circuit.
Control Circuit: The "brain" of the EPS, processing inputs (like torque and rotation angle from the steering wheel) and controlling the entire system.
Communication I/F: Manages data exchange with other vehicle systems via protocols like CAN or Ethernet.
The overall performance of the EPS system hinges on the quality of its individual components. Here’s a look at the critical parts used in each circuit block and how they solve key design challenges.
This circuit requires components that can handle large currents and suppress high-frequency noise generated by the inverter's switching.
Key Challenge: Balancing noise suppression, high power capacity, and a compact footprint.
Component Solution:
Conductive Polymer Hybrid Aluminum Electrolytic Capacitors: These offer the best of both worlds: high capacitance and low ESR (Equivalent Series Resistance). This allows them to effectively smooth voltage and suppress ripple current in a smaller package, handling the high-current demands of the motor.
Power Inductors for Automotive Application: Built with metal magnetic materials, these inductors feature low power loss (low ACR at high frequencies) and support large currents. This contributes directly to higher efficiency and a smaller overall circuit size.
> Explore Panasonic's high-performance Capacitors and Power Inductors designed for demanding automotive applications.
The high-power switching elements (FETs) in the inverter generate significant heat. Managing this heat and suppressing switching noise is critical to prevent component failure.
Key Challenge: Precise temperature measurement and noise suppression in a high-power environment.
Component Solution:
Small, High-Power Chip Resistors: Used on the gate terminals of FETs to suppress driving noise. Advanced resistor patterns and electrode structures allow these components to handle high power in a very small footprint.
NTC Thermistors (Chip-type): These small, highly heat-resistant thermistors are placed near the FETs to provide precise, real-time temperature feedback to the control circuit, enabling proactive thermal management.
> Discover Panasonic's High-Power Chip Resistors and high-reliability NTC thermistors.
This circuit is essential for providing stable power to the microcontroller. It requires robust filtering and efficient voltage conversion.
Key Challenge: Ensuring clean, stable power for sensitive control electronics.
Component Solution: The same high-performance Conductive Polymer Hybrid Aluminum Electrolytic Capacitors and Power Inductors used for noise elimination and smoothing at the input and output stages.
(Figure5: Components used in the DC/DC converter)
Communication lines (like CAN bus) are susceptible to electrostatic discharge (ESD) and other noise that can damage the transceiver IC.
Key Challenge: Protecting sensitive communication circuits from ESD events without degrading signal quality.
Component Solution:
Chip Varistors: These components are designed to suppress ESD noise across a wide range of communication speeds. With capacitance values from 8 pF to 250 pF, they provide effective protection while preserving the integrity of the data signal.
> Protect your communication interfaces with Panasonic's automotive-grade Chip Varistors.
(Figure6: Components used in the communication I/F)
As the automotive industry accelerates towards a future defined by the "CASE" framework, the Electric Power Steering system is evolving from a simple driver-assist feature into a core component of vehicle automation and safety.
This evolution demands a move towards by-wire systems and redundant circuit architectures. To meet this technological leap, engineers must select electronic components that deliver low loss, high heat resistance, high precision, and a compact size.
Panasonic Industry offers a comprehensive portfolio of automotive-grade components designed to meet these stringent requirements, empowering engineers to build the safe, reliable, and efficient EPS systems of tomorrow.
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Component |
Feature |
Low loss |
Small size |
High resistance to heat |
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Low ESR High reliability |
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Large current, low loss High reliability |
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High precision, high resistance to heat |
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Small and light |
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This article offers a technical breakdown of Electronic Stability Control (ESC), a critical technology for preventing vehicle skids and improving driver safety. We will explore its core functions, system architecture, and the key electronic components that make it possible.
Electronic Stability Control (ESC) is an active safety system engineered to enhance a vehicle's steering stability. Its primary function is to prevent wheel skid—where locked wheels slide across the road surface—and to help the driver maintain the intended path. By improving the vehicle's stability during cornering or on slippery surfaces like ice or wet pavement, ESC significantly reduces the risk of traffic accidents.
At its heart, ESC is an intelligent integration of three foundational technologies:
By combining vehicle stabilization, anti-slip, and brake-assist functions, ESC offers a comprehensive safety net. It processes data from various sensors and precisely controls the individual brakes on all four wheels, making meticulous adjustments to the vehicle's position. This capability is especially crucial for maintaining control in emergency evasive maneuvers or on treacherous road conditions.
(Fig. 1 Role of ESC)
While often mentioned together, ESC and ABS have fundamentally different roles. The primary job of an Anti-lock Braking System (ABS) is to prevent the wheels from locking up when a driver brakes hard. This allows the driver to maintain steering control while braking and reduces the vehicle's skidding behavior, but it cannot control a vehicle's sideslip (lateral movement).
Electronic Stability Control, however, is designed specifically to prevent both slip and skids, giving the driver more complete authority over the vehicle's dynamics. Unlike ABS, ESC can actively manage sideslips, which is critical for maintaining stability through sharp curves or on uneven road surfaces.
(Fig. 2 Difference between ABS and ESC)
The adoption of ABS and ESC is widespread and expected to continue growing. This trend places new demands on the underlying technology. To enhance vehicle performance, brake control systems require higher accuracy. Concurrently, there is a strong push for miniaturization to improve fuel efficiency and system redundancy to guarantee safety.
From an electronic component standpoint, these demands create significant engineering challenges. The goals of "high accuracy," "miniaturization," and "redundancy" must be achieved while addressing issues like increased power loss (which generates heat), insufficient heat resistance, and overall power consumption.
The ESC system is a complex network of electronic components working in unison. A typical configuration includes:
(Fig. 3 Overall configuration of the ESC)
The transceiver facilitates communication over data lines (e.g., CAN, Ethernet). These lines are susceptible to external noise and electrostatic discharge (ESD), which can damage the transceiver IC. To mitigate this risk, chip varistors are commonly integrated as a protective measure against ESD events.
[Components used]
ESD noise elimination: Chip varistor
POINT
(Fig.4 Components used in the tranceiver)
This circuit, primarily composed of an FET, an inductor, and capacitors, is crucial for power regulation. Key components include:
Conductive Polymer Hybrid Aluminum Electrolytic Capacitors: Used for noise filtering at the input and smoothing the voltage at the output.
Automotive-Grade Power Inductor: Essential for the voltage conversion process.
High-Precision Chip Resistors: Used for accurate voltage monitoring and feedback.
[Components used]
Noise elimination, switching, and smoothing: Conductive polymer hybrid aluminum electrolytic capacitor
POINTVoltage conversion: Power Inductors for Automotive application
POINTVoltage measurement: Chip resistor (high-precision chip resistor)
POINT
(Fig. 5 Components used in the DC/DC converter)
This circuit uses switching elements (FETs) to convert voltage and drive the motor. The high-frequency switching action is a significant source of electronic noise. To manage this:
A noise filter, consisting of an inductor and a capacitor, is placed at the input to handle voltage fluctuations.
Gate resistors are connected to the switching elements to suppress noise generated during on/off transitions.
[Components used]
Noise elimination and smoothing: Conductive polymer hybrid aluminum electrolytic capacitor
POINTNoise elimination and smoothing: Power Inductors for Automotive application
POINTSuppressing gate-driven noise from the switching elements: Chip resistor (small and high-power chip resistor)
POINT
(Fig. 6 Components used in the motor drive circuit)
The valve drive circuit controls the solenoid that actuates each brake valve. It consists of the solenoid itself, an FET for on/off control, and a diode to protect against voltage surges from the solenoid coil. Similar to the motor drive circuit, a gate resistor is used on the FET to suppress switching noise and ensure clean operation.
[Components used]
Suppressing gate-driven noise from the switching elements: Chip resistor (small and high-power chip resistor)
POINT
(Fig. 7 Components used in the valve drive circuit)
Electronic Stability Control is a sophisticated safety technology that integrates ABS, TCS, and yaw control to stabilize a vehicle, prevent skids, and support the driver in critical situations. As ESC systems become standard, the demand for higher precision, smaller and lighter components, and greater system redundancy will continue to drive innovation in automotive electronics. Engineers are tasked with overcoming challenges related to power efficiency and thermal management to develop the next generation of these life-saving systems.
| Component | Feature | Low loss | Small size | High resistance to heat |
| Conductive polymer hybrid aluminum electrolytic capacitor |
Low ESR High reliability |
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| Power Inductors for Automotive application | Large current, low loss High reliability |
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| High precision, high resistance to heat | |
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| Chip varistor | Small and light | |
The global manufacturing industry is at a significant turning point, particularly in developed countries where labor shortages due to declining birth rates and aging populations pose serious challenges. Factory automation has become an inevitable choice to address these issues. Industrial robots are gaining attention as an effective solution, offering advantages such as:
According to the International Federation of Robotics (IFR), the annual installations of industrial robots worldwide reached approximately 540,000 units in 2023. The total number of industrial robots operating globally in factories has reached 4,281,585 units, marking a record high with a 10% increase from the previous year.
(Figure 1: Operational stock of Industrial robots - World)
This article presents the technical challenges faced by rapidly evolving robots and the passive component solutions from Panasonic that contribute to their realization. It focuses on specific solutions for major technical challenges such as durability in harsh environments and miniaturization.
To further the proliferation of robots, the following challenges must be addressed, along with the necessary solutions:
Ensuring durability in harsh environments
Challenges:
Solutions:
Achieving miniaturization and weight reduction
Challenges:
Solutions:
In factories and production sites, robots are commonly exposed to conditions such as high temperatures, humidity, shock, and vibration. These factors can lead to the deterioration of robot components and systems, increasing the risk of failure and necessitating improved durability. Additionally, industrial robots often require compact designs for operation in limited spaces and integration with other equipment. Addressing these challenges is crucial for the further evolution of robots.
Here we introduce components that contribute to solving the challenges mentioned above.
Panasonic's conductive polymer capacitors offer low ESR (Equivalent Series Resistance) and excellent high-frequency characteristics, providing stable performance that is unaffected by temperature or DC bias. They address issues found in conventional electrolytic and ceramic capacitors, thereby enhancing robot performance.
Let's compare how Panasonic capacitors contribute to miniaturization and component reduction with widely used ceramic capacitors in various applications. A characteristic of MLCCs (Multi-Layer Ceramic Capacitors) is the significant reduction in capacitance due to DC bias, as well as the decline in capacitance at high and low temperatures.
(Figure 2: MLCC DC bias characteristics, temperature characteristics)
In this example, capacitance decreases by 80% when a 15V DC voltage is applied. Additionally, high and low temperatures cause a decrease of about 10%. For instance, if 47µF of capacitance is required with a 15V DC voltage, considering the reduction, the capacitance must be based on 20% of the nominal capacitance value. In the case of a 22µF MLCC, the calculation would be as follows: 22µF × 20% = 4.4µF
47µF ÷ 4.4µF ≈ 10.7 units
In this example, to secure the required capacitance of 47µF for the circuit, more than 220µF of nominal capacitance and over 10 units of 22µF MLCC are necessary. While it is possible to reduce the number of units by selecting MLCCs with larger capacitance, the typical approach is to use multiple low-cost small-capacity MLCCs, as larger-capacitance MLCCs are limited in availability.
Conversely, conductive polymer capacitors do not exhibit significant reductions in capacitance due to DC bias or temperature changes. Therefore, in this example, 10 units of 22µF MLCC can be replaced with a single 47µF conductive polymer capacitor, reducing the number of components and potentially decreasing total costs, including implementation costs, as well as reducing the implementation area.
(Figure 3: Example of replacing MLCC with POSCAP)
To achieve miniaturization and weight reduction of robotic arms, there is an increasing need for compact components and component reduction, along with high vibration resistance. Panasonic's conductive polymer hybrid aluminum electrolytic capacitors support the development of new products that accommodate larger capacities and higher currents, contributing to space-saving by reducing component counts. Additionally, vibration-resistant products are available, supporting vibration acceleration up to 30G for diameters ranging from 6.3mm to 10mm.
Traditionally, when vibration reinforcement was necessary for non-vibration components, bonding (adhesive) was used to secure components. However, using vibration-resistant products can eliminate the need for vibration reinforcement, streamlining customer processes.
(Figure4: Comparison of Panasonic's Hybrid Capacitor standard and vibration-resistant products)
As the deployment of industrial robots advances, the demand for stable operation in high-temperature environments is increasing. The reliability of equipment directly impacts productivity, making the selection of high-reliability components crucial.
Aluminum Polymer Electrolytic Capacitors: SP-Cap
Panasonic’s Aluminum Polymer Electrolytic Capacitor, known as the SP-Cap, is engineered to withstand extreme temperatures, offering an impressive operational lifespan of up to 5,500 hours at 135°C. This remarkable endurance is a significant advantage for industrial robot applications that require reliability in high-temperature environments, especially those that involve constant high loads.
Polymer Tantalum Capacitors: POSCAP
Another noteworthy offering from Panasonic is the Polymer Tantalum Capacitor, commonly referred to as POSCAP. These capacitors are designed to provide robust performance in high-temperature conditions, with a guaranteed operational lifespan of up to 1,000 hours at 125°C. The POSCAP series is particularly well-suited for applications that demand high capacitance in a compact form factor, downsized to B case size, and can replace MnO2 capacitors with safety features.
Aluminum Polymer Solid OS-CON: Exceptional Longevity
Among Panasonic's offerings, the Aluminum Polymer Solid OS-CON capacitors stand out for their exceptional longevity and performance, with an operational lifespan of up to 20,000 hours at 105°C. These capacitors are specifically designed to provide extended operational life, making them ideal for applications that require long-term reliability in high-temperature environments. For example, the OS-CON SVT series features a remarkably long expected lifespan of 12.8 years at 90°C, contributing to the stable operation and longevity of robotic arms expected to be used in high-temperature and harsh environments.
Additionally, Panasonic's conductive polymer capacitors, including the SVT series, utilize conductive polymers with high electrical conductivity as electrolytes, resulting in significantly lower ESR compared to general aluminum electrolytic capacitors and tantalum capacitors. This reduction in component count and space on robot internal circuit boards contributes to the miniaturization of robots.
(Figure 5: Benefits of using low ESR products)
Panasonic's Metal Composite (MC) type power inductors feature a metal composite core made from proprietary magnetic materials and an integrated molding structure. They possess superior characteristics within a small body size, offering excellent heat and vibration resistance, ensuring high reliability suitable for robotic applications.
The comparison table below highlights the superior magnetic saturation characteristics, thermal stability, heat resistance, vibration resistance, and ACR (AC resistance) of MC types compared to ferrite types.
(Figure 6: Comparison of Ferrite Type and Metal Composite Type)
An example of data plotted under different conditions (25°C, 100°C, 125°C, 150°C) for the magnetic saturation characteristics (DC superimposition characteristics) of MC-type and ferrite-type inductors is presented. Magnetic saturation characteristics refer to the phenomenon where inductance sharply decreases at a specific current value when DC is applied, making them one of the key characteristics.
Generally, ferrite types are known for their pronounced saturation characteristics, as indicated by the graph, where inductance sharply decreases with increased DC bias and also varies with temperature. In contrast, Panasonic's MC type does not exhibit a rapid decrease in inductance, indicating saturation, and shows minimal variation with temperature. This is a crucial point for power inductors, which are accompanied by heat generation.
(Figure 7: MC Type vs. Ferrite Type comparison of magnetic saturation characteristics and thermal ttability)
Panasonic's MC type inductors ensure high reliability and are suitable for automotive applications, undergoing rigorous reliability testing. Heat shock: -40°C ⇔ 150°C for 2,000 cycles, and heat resistance at 150°C for 2,000 hours are guaranteed. Below are standard automotive test items and conditions.
(Figure 8: Reliability test example (Automotive standard)
(Figure 9: Features and strengths of vibration-resistant products)
When the frequency of the current flowing through a conductor increases, the skin effect and proximity effect cause the current to concentrate on the surface of the conductor, resulting in lower density in the center and higher density on the surface. Consequently, the resistance component increases at high frequencies, and in inductors, this increased resistance component is referred to as AC resistance (ACR).
The graph below compares the AC resistance (ACR) of MC-type and ferrite-type inductors. As the frequency increases and ACR rises, AC losses increase, leading to higher heat generation. As indicated by the graph, the increase in ACR for the MC type is smaller than that for the ferrite type, indicating lower losses and heat generation even at high frequencies.
(Figure 10: Comparison of ACR-Frequency characteristics between ferrite type and metal composite type)
The following components are recommended for use in circuits.
(Figure 11: Target circuit points and benefits of Panasonic inductors)
The figure below illustrates the difference in heat generation resulting from different resistance values when a current of 4A is applied. For example, reducing the resistance from 10mΩ to 2.5mΩ can decrease heat generation by approximately 33°C.
(Figure 12: Difference in heat generation due to resistance values with 4a current)
Panasonic has developed current detection chip resistors with significantly lower resistance values than conventional products. The use of these resistors reduces heat generation, thereby enhancing energy efficiency. The specific measures taken by Panasonic include:
Thick Film Type
Anti-sulfur resistors enhance reliability in environments with high sulfur content. Typical areas with elevated sulfur exposure include locations near volcanoes, hot springs, highways with high vehicle emissions, and industrial sites using cutting oils or rubber-based products. Even in general environments, sulfur can emanate from materials such as lubricants or greases used in cooling fan motors, rubber seals for packing or vibration isolation, and certain mold resins. Silicone-based coating materials can accelerate sulfur-induced corrosion (sulfuration). Thus, in such conditions, the use of chip resistors designed with sulfur resistance is essential.
Panasonic's anti-sulfur chip resistors achieve superior reliability by replacing traditional silver electrode materials with highly sulfur-resistant alternatives. Panasonic offers two resistor series tailored to specific requirements: one focused on absolute performance and another optimized for longevity, balancing performance and cost considerations.
Below are the immersion test results comparing Panasonic’s anti-sulfur chip resistors against general-purpose resistor electrodes when immersed in sulfur-containing oil.
(Figure 13: Immersion test results comparing anti-sulfur chip resistors and general-purpose resistors in sulfur-containing oil)
In typical resistor electrodes, the low palladium content commonly results in failures (disconnections) after approximately 100 hours of sulfur exposure. In contrast, Panasonic’s ERJU series resistors, featuring high-palladium silver electrodes, exhibit no disconnection even after 3,000 hours, substantially enhancing reliability. A direct correlation exists between palladium content and time-to-disconnection; thus, the ERJU series is designed to withstand exposure exceeding 12,000 hours without failure. The ERJS series, with gold-based electrodes, demonstrates even higher reliability, showing no measurable change in resistance values after 3,000 hours.
Standard chip resistors typically have an upper operating temperature limit of 155°C. Furthermore, resistors inherently experience self-heating (Joule heating) during operation, necessitating power derating when ambient temperatures exceed approximately 70°C. Panasonic addresses this limitation with its heat-resistant ERJH series resistors, which feature an increased maximum operating temperature of 175°C. Consequently, power derating for this series begins at a higher ambient temperature of 105°C, enabling stable, high-power operation in more demanding, high-temperature environments.
Passive components play a crucial role in enhancing the performance of a robot. The appropriate selection of capacitors, inductors, and resistors is key to addressing challenges related to durability in harsh environments and miniaturization. Panasonic is committed to contributing to the advancement of the robotics industry through innovative passive component solutions. We will also strengthen our customization options and technical support to meet the needs of our customers.
Component |
Product Feature |
Recommend Series |
High voltage |
Large current |
Low loss |
Small size |
High resistance to heat |
High precision |
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Conductive Polymer Aluminum Electrolytic Capacitors (SP-Cap) |
Low ESR Low ESL Long Life Small size |
JX, KX, TX, JZ, KZ, TZ series |
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Low ESR Small size High frequency Heat resistance High reliability |
TDC, TQC series |
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Low ESR Long Life Excellent noise reduction |
SVPT, SVT series |
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Low ESR High withstanding Voltage High reliability Vibration resistance |
Anti-vibration type |
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Large current Low loss Small Size |
LP, LE series |
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High precision High resistance to heat |
Anti-pulse: ERJP Thin film high precision: ERA*A/ERA*V Shunt: ERJ*W, ERJB/D Anti-sulfurated: ERJU/ ERJS |
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The characteristic viewer is a tool that graphically displays various characteristics of selected components on frequency and temperature axes. It facilitates easy verification of component characteristics such as changes in characteristic values within the operating frequency range, serving as a useful tool for component selection.
Industrial & Automotive use LC filter simulator user registration - Panasonic
The industrial/automotive LC filter simulator is a content tool that simulates attenuation characteristics when filters are configured using our power inductors and aluminum electrolytic capacitors suitable for industrial and automotive applications. Please utilize it for component selection in industrial and automotive filters.
Features:
- Filter circuit simulation is possible in π, T, and L configurations.
- Simultaneous comparison of 5 circuits is possible.
- Supports parallel and series connection of components.
- Allows output of simulation results (attenuation characteristics) in graph and CSV formats.
Hybrid/Aluminum Electrolytic capacitor Estimated Lifetime Calculation Tool
Lifetime calculations provide critical insights into how Panasonic hybrid and aluminum electrolytic capacitors will perform under specific conditions, helping to predict potential failures before they occur. By analyzing factors such as temperature, voltage, load conditions, and environmental influences, engineers can estimate the expected lifespan of these capacitors.
International Federation of Robotics, 2024, September 24, Record of 4 Million Robots in Factories Worldwide, IFR International Federation of Robotics, https://ifr.org/ifr-press-releases/news/record-of-4-million-robots-working-in-factories-worldwide
Are you curious about how to get the most out of the Grid-EYE sensor from Panasonic Industry? Our latest YouTube video dives deep into the topic of of thermography and human detection!
Explore how a human subject's signature changes with distance from the sensor. Did you know that as a person moves further away, their heat signature diminishes, making detection increasingly challenging? With the Grid-EYE's 8x8 pixel array, we explain the intricate relationship between distance, field of view, and accurate temperature readings.
Whether you're in security, digital signage, or the medical field, understanding these concepts is crucial for effective tracking. So - don’t miss that insightful short video.
For questions or further information, feel free to reach out or visit our website at Panasonic Industry.
In the world of passive components, aluminum electrolytic capacitors have been a popular choice due to their impressive capacitance-to-volume ratio, making them ideal for applications where every bit of space counts. They are commonly used for functions like voltage smoothing in rectified AC circuits, noise filtering, and audio frequency amplification. However, in the past decade, polymer and hybrid polymer capacitors have gained traction, boasting advantages such as extended lifespans, higher maximum operating temperatures, and lower equivalent series resistance (ESR). Despite these advancements, many engineers still favor traditional electrolytic capacitors for their affordability, especially in scenarios where space is less of an issue.
The FN series from Panasonic marks a significant advancement in aluminum electrolytic capacitor technology. Tailored to address the market demand for smaller sizes and greater capacitance, the FN series provides an attractive option for engineers looking for dependable performance without sacrificing size or budget.
The FN series distinguishes itself with several notable features:
The FN series is an evolution from standard electrolytic capacitor series in the market, addressing several limitations while enhancing performance. Key improvements include:
The FN series is well-suited for a variety of applications across different sectors. In the automotive sector (see image), it supports advanced driver-assistance systems (ADAS), electric power steering (EPS), battery management systems (BMS), and charging stations, showcasing its versatility and performance in high-stakes environments. Specifically, it is ideal for safety systems like ABS and electric stability control, as well as engine and power train control systems, where low ESR and high-temperature performance are crucial.
In the industrial domain, the FN series is ideal for programmable logic controllers (PLCs), I/O modules, and measuring equipment, all of which demand precision and stability.
Last but not least, the FN series is an ideal choice for applications from the smart home ecosystem. It be effectively utilized in smart meters, smart speakers, and lighting control systems, where compactness and reliability are essential.
The FN series from Panasonic represents a significant advancement in aluminum electrolytic capacitor technology. By combining miniaturization with increased capacitance and improved reliability, the FN series addresses the evolving needs of engineers in various industries. While polymer and hybrid capacitors have their place in modern electronics, the FN series reinforces the value of traditional electrolytic capacitors, offering a balanced solution that meets both performance and cost requirements. As the demand for compact, efficient components continues to grow, the FN series stands out as a reliable choice for engineers looking to optimize their designs.
Epilogue: Panasonic's Commitment to E-Cap Technology and Business
Through significant ongoing investments, Panasonic Industry has enhanced its electrolytic capacitor production capacity by 10%. The company is dedicated to continual performance improvements, particularly in lifespan, capacitance-to-size ratio, temperature ratings, and ESR. While some competitors are withdrawing from the market, particularly in the realm of through-hole components, Panasonic remains steadfast in its commitment to providing high-performance parts. For Panasonic, electrolytics are undeniably a staple of the industry.
Panasonic Industry is committed to supporting its customers with a comprehensive range of film capacitor solutions, even as certain suppliers announce an "End of Life" for their products. This development has impacted various film capacitor manufacturers, creating a gap in the market.
In response, Panasonic Industry is proud to offer a variety of alternative film capacitor series that meet and exceed the performance and reliability standards required by our customers. Panasonic’s robust portfolio ensures that clients can seamlessly transition to the brand’s products, minimizing disruptions in their operations.
| Affected series of competitors |
Panasonic alternative series |
| C4AS / C4BS | ECWH / ECQE(F) / EZPE / EZPV |
| F611 | ECQE(F) |
| F612 | ECQE(B) |
| F622 | ECQE(F) |
| GPC – F117 | ECWFD |
| LDE | ECHU(X) / ECHU(C) |
| MMK – F602 | ECQE(F) |
| PHE450 – F450 | EZPV / ECWH /ECQE(F) |
| R60 | ECWH / ECQE(F) / EZPE / EZPV |
| R66 | ECQE(F) |
| R76 | ECWH / ECQE(F) / EZPE / EZPV |
Panasonic Industry recognizes the challenges customers face in the current market and is dedicated to providing reliable alternatives that enhance product performance.
For more detailed information about film capacitor offerings and support for your business, please contact capacitor@eu.panasonic.com.
The cooling system pump is responsible for moving water through the cooling system, helping to prevent overheating of various equipment. This pump typically requires between 30 W and 100 W of power to function. It consists of an impeller, a motor, and an inverter, all housed in a cylindrical outer casing. In this article, we will explore the pump's functions, its configuration, and the electronic components that make it work.
Understanding the cooling system pump
In vehicles, the cooling system is designed to manage the heat generated by components like the battery and motor. It does this by circulating water through pipes in the cooling unit (also known as the jacket) surrounding these components. The pump forces water to flow through these pipes, and it generally operates with a power range of 30 W to 100 W. The main parts of the pump include an impeller, a motor, an inverter (which controls the motor), and a circuit board, all contained within a cylindrical casing.
Market trends and demand for cooling system pumps
As the number of vehicles—both electric and those with internal combustion engines—continues to rise, the demand for cooling system pumps in these vehicles is also expected to grow. Additionally, as equipment like batteries and inverters increase in power output, they generate more heat, leading to a greater need for efficient cooling systems and more powerful pumps.
To meet these needs, the electronic components in cooling systems must have key features: "high current capacity," "low energy loss," "high heat resistance," and "precise temperature control."
Circuit configuration of a cooling system with a pump overall setup
• Noise Filter: Removes interference using a coil and a capacitor.
• Voltage Conversion Circuit: Changes voltage using switching elements like FETs.
• Current Measurement Unit: Monitors the output voltage to the motor.
• Gate Drive Circuit: Controls the switching elements.
• Control Circuit: Manages the conversion circuit and other functions.
• DC/DC Converter: Powers the control circuit.
• Communication interface: Allows communication with external devices.
Detailed look at individual circuits and components
Noise Filter: This component reduces noise from both inside and outside the system to prevent malfunctions, typically using a combination of a large coil and a capacitor.
Components used:
Noise elimination and smoothing: Conductive polymer hybrid aluminum electrolytic capacitor:
It provides high capacitance, low equivalent series resistance (ESR), and excellent noise suppression, making the circuit smaller and more efficient.
Voltage conversion: Power inductors used in automotive applications help minimize power loss and handle large currents, enhancing efficiency.
Voltage conversion circuit: This circuit uses switching elements that can create noise when turned on and off. To reduce this noise, resistors are added to the gate terminals of the FETs.
Components used:
Chip resistor: Small and capable of high power, helping to minimize circuit size.
Control circuit: This part continuously checks the water temperature using a sensor. Based on the temperature readings, it adjusts the pump's speed to maintain the proper temperature.
Components used:
Temperature sensor: Designed for automotive use, it withstands extreme temperatures from -40°C to 200°C.
DC/DC converter: Made up of FETs, coils, and capacitors, this component uses conductive polymer hybrid aluminum electrolytic capacitors to smooth voltage output and eliminate noise.
Communication interface: This circuit connects to external equipment via communication lines (like CAN or Ethernet). To protect against noise or static electricity, chip varistors are used to prevent damage.
Components used:
Chip varistor: It suppresses electrostatic discharge (ESD) noise without affecting the quality of communication.
Conclusion
The cooling system plays a vital role in circulating water to cool equipment and prevent overheating. As the number of vehicles, including electric and gas-powered ones, continues to grow, so will the need for effective cooling systems and pumps. With rising power outputs from various components, the demand for enhanced cooling performance is critical, necessitating pumps with higher output. Thus, the electronic components used in these systems must offer features like high current capacity, low energy loss, high heat resistance, and precise temperature control. Panasonic Industry provides a range of products suitable for use in cooling systems.
Have a look at the mentioned products also in Farnell stock:
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