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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 |
|---|---|
| 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:
Different kinds of electronic devices employ AC/DC converters as instrument to transform commercial AC power into DC power. They are necessary since the majority of electrical loads operate on DC rather than AC voltages. The size of an AC/DC converter varies depending on how much power the device needs. From the perspectives of saving space and portability, the smaller the size as compared to the same power, the better.
Downsizing has historically been a gradual process ever since AC/DC converters switched from linear to switching approaches.
But as is sometimes the case with AC adapters for notebook PCs, there have been notable reductions in size in recent years.
Such dramatic advances are frequently brought about by the introduction of low-loss GaN (gallium nitride) as a switching element in place of traditional Si, in addition to ongoing improvements in circuit topology.
Since approximately the year 2000, GaN has been used in power supplies. But the use of practical GaN has been gaining tremendous momentum in recent years.
Due to societal developments including the rise of mobile work and power shortages, there has been a growing demand for smaller size and improved efficiency. Additionally, GaN's own quality and productivity improvements have been matched.
GaN switching elements have lower switching losses than Si switching elements because they switch more quickly. As a result, if the switching frequency is kept constant compared to conventional Si, efficiency will be increased, heat will be lowered, and heat dissipation components will be made simpler.
Additionally, if employing smaller passive components, it is acceptable to use a higher switching frequency. GaN can maintain the same high efficiency that Si offered at a low switching frequency, even at greater switching frequencies.
Modern power supply designs are generally regarded as acceptable if they maintain the high power efficiency that earlier technologies attained. GaN's low loss advantage therefore frequently causes designs to be scaled down.
In order to reduce the size of the output capacitors for AC/DC converters that use GaN switches, Panasonic Industry offers a large selection of suitable polymer capacitors.
Let's first examine the operation of an output capacitor.
The output capacitor adds to the clean DC current output to the next circuit by absorbing the ripple current of the AC/DC converter. The capacitor will always produce ripple voltage when it takes in ripple current. This ripple voltage must be less than the limit values established for the application's safe functioning during design verification, which are typically less than 5% of the output voltage.
The impedance of the capacitor is the primary component for obtaining minimal ripple on a DC output voltage. The fundamental relationship is ripple voltage = ripple current x impedance (V=I*Z). Therefore, it is best to utilize capacitors with the lowest possible impedance at the switching frequency (where ripple current occurs).
GaN's reduced switching loss makes it possible to employ switching frequencies up to 500 kHz, compared to traditional Si's 100 kHz.
Polymer capacitors have a far lower impedance in this high-frequency region than with the more common liquid electrolytic capacitors. As a result, polymer capacitors can significantly lower ripple voltages, making them the optimum output capacitors for AC/DC converter systems that use GaN.
A low ESR conductive polymer substance is used as the electrolyte to provide polymer capacitors their low impedance.
Because of the low ESR, it can withstand more ripple currents than electrolytic capacitors.
Additionally, unlike liquid electrolytic capacitors, conductive polymer has a solid electrolyte, therefore its properties do not degrade over time or in low-temperature environments. These benefits of polymer capacitors influence client designs in various ways.
In some circumstances, raising the switching frequency can lower capacitance, which can result in significant cost and size reductions. Let's discuss one example of this.
The high-frequency AC/DC converter used in the evaluation example below operates between 200 and 400 kHz. Compared to electrolytic capacitors, polymer capacitors are able to implement the design with a significantly smaller area and fewer components.
This is a result of the aforementioned polymer capacitor's good temperature and frequency properties.
Electrolytic capacitor 63V 390uF vs Polymer capacitor 63V 33uF
At 48V output of the AC/DC converter
Measure the output ripple voltage at a maximum load of 3.2A including at lowest operating temperature for the worst condition.
Compare the measurement result between the originally equipped electrolytic capacitor 63V 390uF x 3 and proposed Panasonic polymer capacitor 63V 33uF x 1-3.
Even though the polymer capacitor has a smaller capacitance, its excellent frequency characteristics suppress ripple voltages to the same level.
When looking at the lowest operating temperature -30°C, it shows a possibility to design only with a single polymer capacitor.
And this will be stable even at the end of life (after 50,000 hours).
The need for these high-frequency AC/DC converters, which is growing with GaN adaptations, is being met by Panasonic.
Panasonic is a leader in polymer capacitors and offers a range of solutions up to 100V that make use of our special high-performance and high-reliability technology. They are extensively utilized for 48V output for network equipment, 24V output for industrial equipment, and 5-20V output, which is commonly used in consumer devices.
In response to current issues with power shortages, more and more devices—such as cars, data centers, and USB-PD—are switching to high-efficiency 48V power distribution. Then, in addition to GaN, polymer capacitors will be more active.
*Hybrid＝Polymer＋Liquid electrolyte
Known as pioneers of metal composite power inductor technology, Panasonic Industry has undoubtedly made a name for itself - but the industries’ rapid developments and increased demands on the specs of passive components wouldn’t allow any rest on the laurels:
Depending on the area and specific application, the demands are as high and differentiated as never before: From higher currents, better resistance to vibrations, lower losses for specified frequencies up to serving the trend for miniaturization: In the following, we attempt to illustrate the power inductors’ diversification in a brief summary:
1) High Power
As the number of electric components per vehicle is ever increasing, the required currents are increasing accordingly. Since the market introduction of the Panasonic MC series in 2004, the current specification of the ETPQ power choke coils raised steadily. Currently, the ETQP8M***JFA - series in the dimensions of 12x12mm reveals the highest-rated current specification with 53A. Due to the newly developed integral construction, it also comes with very high resistance of up to 30G against vibrational shocks, which is unmatched for metal composite power inductors of that size.
Picture: ETQP8MR68JFA
Panasonic Industry follows the automotive industry’s needs to offer ever smaller and more compact power inductors with ever-higher current capabilities. Based on the innovative design of the ETQP8M***JFA - series, the ETQPAM***JFW - series has been developed with dimensions of 15x15x10mm and current capabilities of up to 73A. This innovative series significantly exceeds the current capabilities of comparable products in the market due to reduced DC-losses and an optimized magnetic flow within the metal core. The ETQPAM***JFW - series is specifically targeted to 48V-DCDC converters which require very high current capabilities - and enables customers to further downsize their systems.
2) Robustness
Since the first developments on a metal composite power inductor for automotive applications started at Panasonic, robustness has been a major topic. As electronic systems became more and more integrated, they got positioned closer and closer to the engines of a vehicle. This of course requires high robustness against vibrational shocks to guarantee long-term mechanical durability. At the time of introduction, the MC series was already a major improvement compared to conventional ferrite inductors with specified robustness of 10G. Over the years, the design and production process of Panasonic power choke coils improved remarkably. This leap in know-how resulted in the development of the ETQP*M***YS* - series, offering industry-leading vibration robustness of up to 50G. It is specifically targeted at ECUs which are situated in the engine itself or mechanical-electrical-integrated ECUs.
Picture: ETQP5MR68YSC
3) Low Power Loss
As another area of research, Panasonic Industry investigates the development of power choke coils with minimal losses. The latest innovation in this area is the ETQ-P3M***HF* - series optimized for frequencies up to 5MHZ. It was specifically developed for power circuits in ADAS applications as well as navigation and telematics systems. Both the magnetic material and the winding technology have been developed in-house at Panasonic Industry, resulting in a compact high precision and high-performance coil, that comes with a convincingly reduced volume ratio of 30% when compared to existing products.
Picture: ETQP3M100HFN
4) Miniaturization
As the electronic industry places a great focus on efficiency, engineers are expected to create products that are thinner, lighter and smaller. The first metal composite power choke coils introduced by Panasonic measured 10x10mm. Over the years, the PCC family got more and more compact members - 8x8mm, 7x7mm, 6x6mm and 5x5mm. Smaller and smaller housings are made possible due to a new innovative production process and are in great demand for ADAS, Radar and Lidar applications.
5) High current (Industry)
With its extensive knowledge about metal composite power inductors, Panasonic Industry also supports industrial and consumer applications. The latest developments are focused on high current applications for Server and GPU accelerators, where the power inductors are designed in DC/DC converters of step-down circuits of CPU or GPU circuits.
The world of electronic innovations is spinning faster than ever - which actually means: as fast as the technology of the installed components allows.
That “one inductor for everything” no longer exists - the demands have become highly diversified, so it pays for every product designer to remain attentive and up to date which specs would be the right ones for their own project.
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