fujitsu ev / phv relays · ftr-k3-wg, -pv version with 1.5mm gap is available ftr-k3-ws, ......
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Copyright 2018 FUJITSU COMPONENT LIMITED
Fujitsu EV / PHV Relays
Fujitsu Components America, Inc.Fall 2018
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High capacity of quick charger High voltage, high current requirement
Now up to50kW
2018Rated 150kW
2017Max. 150kW
Non-Hydrogen Gas for Low Cost & Small Size
High capacity of normal charger 3.3kW 6.6kW
Now up to 3.3kWFTR-K1 relay 16A, 250VAC
New design 6.6kWFTR-K5 relay 32A, 277VAC
2018Sample
FTR-E1
250A
FTR-B3
FTR-K5Under development
FTR-K3FTR-K1
FTR-E3Under development
0.1A 16A 32A 400A
AC load 250VAC
DC load 400~750VDC
Roadmap for EV & PHV Relays
Copyright 2018 FUJITSU COMPONENT LIMITED1
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Target Relay Application (1) Relay Application
Copyright 2018 FUJITSU COMPONENT LIMITED
Battery
Inverter
Motor
Generator/Engine
DC
/AC
Battery UnitFTR-E3: Main switch for main battery disconnect from motor sideUnder DevelopmentFTR-E1: Pre-charge for protection from capacitor inrush
Quick Battery Charger (QBC)FTR-E3: DC-high voltage switching for disconnection from quick DC chargerUnder Development
Charger Cable BoxFTR-K3: Additional function in cable for safety operation
Quick Charger Stand
Charger Cable Box
Battery Unit
QBC
OBC
On Board Charger (OBC)FTR-E1: DC-side switching for disconnect from main batteryFTR-K1: AC-side switching for disconnect from outside AC charger
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Relay Application
Copyright 2018 FUJITSU COMPONENT LIMITED
Charger Stand
Control Box Battery
Battery ControllerFTR-B3: Battery voltage monitor
Grid Power
Quick Charger StandFTR-E3: DC-high voltage switching for disconnect in quick DC chargerUnder Development
Normal Charge
AC/DC
Charger StandFTR-K3: Additional function in charger stand control box
Quick Charge
Charger Cable BoxFTR-K3: Additional function in cable for safety operation
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Target Relay Application (2)
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Application Proposed Relay Status
Relay #1 Main Switch relayFTR-E3 (250A, 450VDC class) Under development
New development(400A, 1,000VDC class)
Under development
Relay #2 Pre-Charge relay FTR-E1 (30A, 450VDC class) Mass Production
Relay #3 Quick Battery Charger(QBC) relay FTR-E3 (250A, 450VDC class) Under development
Relay #4 On Board Charger (OBC) DC relay FTR-E1 (30A, 450VDC class) Mass Production
Relay #5 On Board Charger (OBC) AC relayFTR-K1 (16A, 250VAC class) Mass ProductionFTR-K5 (32A, 250VAC class) Under development
Relay #6 Charger Cable relay(in charger cable box) FTR-K3 (32A, 250VAC class) Mass Production
(Relay #7) Battery Controller(for voltage monitor) FTR-B3 (1mA, 400VDC class) Mass Production
(Relay #8) Vehicle to Home FTR-E1 (30A, 450VDC class) Mass Production
Proposed Relays for EV & Charger Stand
Copyright 2018 FUJITSU COMPONENT LIMITED4
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Relay #1: Main Switch FTR-E3 Series
Arrangement : 1 form A (no-polarity) Contact rating : DC 450V/150A Carrying current : 150A @ +85 Enclosure : Plastic sealed type Dielectric strength : 2,500VAC (coil-contact)
2,500VAC (open contacts)
Feedback from Customers
Copyright 2018 FUJITSU COMPONENT LIMITED
FTR-E3 Existing project In future, 2021~
Contact rating DC 450V/150A DC 450V/250A DC 1,000V/400A
Contact life @rating 100 ops 100 ops, 1,000 ops 100 ops, 1,000 ops
Short term current NA 3,000A 6,000A~, 20,000A~
Shock resistance 10G 30G or more 30G or more
E3 Modify Ver. New Development
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Relay #2: Pre-Charge FTR-E1 Series
Arrangement : 1 form A (no-polarity) Contact rating : DC 450V/20A, 30A (-HA) Electrical life : 75k @ DC 450V/10A
10k @ DC 450V/20A100k @ DC 450V/20A - Making
Carrying current : 40A, 1H @ +85 Enclosure : Plastic sealed type Dielectric strength : 5,000VAC (coil-contact)
2,500VAC (open contacts) Size (L x W x H) : 43.6 x 28.3 x 36.8mm Status : Mass Production (MP)
Copyright 2018 FUJITSU COMPONENT LIMITED6
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Relay #3: Quick Battery Charger FTR-E3 Series
Arrangement : 1 form A (no-polarity) Contact rating : DC 450V/150A Carrying current : 150A @ +85 Enclosure : Plastic sealed type Dielectric strength : 2,500VAC (coil-contact)
2,500VAC (open contacts)
Feedback from Customers
Copyright 2018 FUJITSU COMPONENT LIMITED
FTR-E3 Existing project In future, 2021~
Contact rating DC 450V/150A DC 450V/250A DC 1,000V/400A
Contact life @ rating 100 ops 100 ops, 1,000 ops 100 ops, 1,000 ops
Short term current n.a. 3,000A 6,000A~, 20,000A~
Shock resistance 10G 30G or more 30G or more
E3 Modify ver. New development
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Relay #4: On Board Charger / DC-side FTR-E1 Series
Arrangement : 1 form A (no-polarity) Contact rating : DC 450V/20A Electrical life : 75k @ DC 450V/10A
10k @ DC 450V/20A100k @ DC450V/20A - Making
Carrying current : 40A, 1H @ +85 Enclosure : Plastic sealed type Dielectric strength : 5,000VAC (coil-contact)
2,500VAC (open contacts) Size (L x W x H) : 43.6 x 28.3 x 36.8mm Status : Mass Production (MP)
Copyright 2018 FUJITSU COMPONENT LIMITED8
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Relay #5: On Board Charger / AC-side FTR-K1 Series
Arrangement : 1 form A or C Contact rating : AC 250V/16A Electrical life : 20k @ rating, +85 Carrying current : 20A, 1H @ +85 Enclosure : Plastic sealed or flux-free Status : Mass Production (MP)
FTR-K5 Series Arrangement : 1 form A Contact rating : AC 250V/32A Electrical life : (1) 7k @ rating, +85
(2) 30k @ rating, +85 Carrying current : 40A, 1H @ +85 Enclosure : (1) Plastic sealed, (2) flux-free Status : Under Development
Copyright 2018 FUJITSU COMPONENT LIMITED
29.0 x 12.7 x 15.7 mm
33.3 x 16.5 x 27.5 mm
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Relay #6: Charger Cable Box FTR-K3 Series
Arrangement : 1 form A Contact rating : AC 250V/25~32A Electrical life : 30k @ rating, +20 Enclosure : flux proof type Status : in Mass Production (MP)
Safety Standard Study
According to IEC62752* 1.8mm contact gap is required FTR-K3-WG, -PV version with 1.5mm gap is available FTR-K3-WS, -PS version with 1.8mm gap is available
Copyright 2018 FUJITSU COMPONENT LIMITED
30.1 x 15.7 x 23.3 mm
-WG -WS -PV -PSRating 25A 25A 32A 32AContact gap > 1.5mm > 1.8mm > 1.5mm > 1.8mm
* IEC62752: In-cable control and protection device for mode 2 charging of electric road vehicles (IC-CPD)
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Relay #7: Battery Controller Relay FTR-B3 Series
Arrangement : 2 form C (no-polarity) Contact rating : DC 400V/1mA Electrical life : 100k @ rating, +20 Insulation resistance : 1,000M Dielectric strength : 1,500VAC (coil-contact Surge strength : 2,500V (2x10s, coil-contact Enclosure : Plastic sealed or flux-free Status : Mass Production (MP)
Copyright 2018 FUJITSU COMPONENT LIMITED
7.2 x 10.6 x 5.45 mm
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Modification / Improvement Idea (FTR-E3) Target Modification of FTR-E3 RelayMain target
DC 450V/250A as contact rating > 30G as shock resistance Small size Low cost
Copyright 2018 FUJITSU COMPONENT LIMITED
0
20
40
60
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100
120
140
Current carrying Shock resistance Size (volume) Target cost
Com
paris
on ra
tio [%
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Comparison between Competitor Relay (100%)
Competitor relayExisting "FTR-E3"Target of new/modified FTR-E3
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Technology to achieve main target Technology for Arc extinguish
Wide contact gap Permanent Magnet Cooling by Hydrogen gas
Modification / Improvement Idea (FTR-E3)
Copyright 2018 FUJITSU COMPONENT LIMITED
Capsule with Hydrogen gas
Technology to achieve main target Technology for Arc extinguish
Wide contact gap Permanent Magnet Cooling by Hydrogen gas Additional arc-extinguishing plate
For COST & SIZE
No plate With the plate
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Modification / Improvement Idea (FTR-E3) Technology to achieve main target Effect of arc-extinguishing plate
By placing arc-extinguishing plate in the middle of arc route, the effect was confirmed as shorter arcing time.
Copyright 2018 FUJITSU COMPONENT LIMITED
Arc time: 1.79ms
200A
0A
Unable to extinguish arc
600VDC-200AWithout plate With plate
plate
600VDC-200A
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DC Relay for Main Switch / Quick Charging
Copyright 2018 FUJITSU COMPONENT LIMITED
FTR-E3 Modified Version & New Development Relay FTR-E3 Modified Version: DC 450V / 250A New Development Relay: DC 1,000V / 400A
FTR-E3 Modify Ver. New DevelopmentContact rating DC 450V/250A DC1,000V/400AContact life @ rating 1,000 ops 1,000 ops
Make only 100,000 ops 100,000 opsShort term current 3,000A 20,000A~Shock resistance 30G or more 30G or more
Plan / ScheduleModified version of FTR-E3 (450V/250A) 2019 MP ()New Development (1,000V/400A) 2019 ES (Plan)
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Copyright 2018 FUJITSU COMPONENT LIMITED16
Fujitsu EV / PHV RelaysSlide Number 2Target Relay Application (1)Target Relay Application (2)Slide Number 5Relay #1: Main SwitchRelay #2: Pre-ChargeRelay #3: Quick Battery ChargerRelay #4: On Board Charger / DC-sideRelay #5: On Board Charger / AC-sideRelay #6: Charger Cable BoxRelay #7: Battery Controller RelayModification / Improvement Idea (FTR-E3)Modification / Improvement Idea (FTR-E3)Modification / Improvement Idea (FTR-E3)DC Relay for Main Switch / Quick ChargingSlide Number 17