Why hybrid electrification?Three-phase motor drive architecture source: ON Semiconductor

In the construction and mining industries, different types of heavy equipment are used. The blog focuses on earth-moving vehicles such as dump trucks, excavators and bulldozers. It is estimated that by 2025, 1.1 million of these cars will be sold globally. On a global scale, we have witnessed the 2020/21 blockade, curfews and other restrictive measures that have brought construction and mining to a near halt and have had a huge impact on the economy.

Author: Pramod Patil

In the construction and mining industries, different types of heavy equipment are used. The blog focuses on earth-moving vehicles such as dump trucks, excavators and bulldozers. It is estimated that by 2025, 1.1 million of these cars will be sold globally. On a global scale, we have witnessed the 2020/21 blockade, curfews and other restrictive measures that have brought construction and mining to a near halt and have had a huge impact on the economy. This market segment. Despite the struggle, it is expected to regain momentum due to the following trends:

As shown in the chart below, three key megatrends have been observed in the construction vehicle market.

Electrification: Driven by strict emission regulations.

Operator comfort: Driven by government safety regulations and productivity requirements.

Automation/Remote Drive: Driven by productivity, efficiency and safety requirements.

Why hybrid electrification?Three-phase motor drive architecture source: ON Semiconductor
Figure 1. Major trends in the construction vehicle market

Why hybrid electrification?

Heavy vehicles are used for construction and earthmoving activities in urban areas. Usually, the operation site is located in a low-emission zone or a zero-emission zone. The realization of strict emission and noise standards and the need to reduce fuel consumption have prompted engineering vehicle manufacturers and first-tier suppliers to adopt electrification. These heavy-duty vehicles are very energy intensive, which leads to a large investment in battery costs, so the current fully electrified method is not economically feasible. Therefore, the manufacturer adopted a mild mixing method to meet the upcoming emission and noise standards.

What does electrification mean for this market segment?

Fuel costs can be saved up to 10-12%.
It can reduce CO2 emissions by up to 12%.
The fuel efficiency is as high as 17%.
Reduce noise pollution.
Enhance the safety and comfort of the operator.

In a typical hybrid engineering machinery, as shown in Figure 2, high-power functions such as hydraulic and auxiliary electrical loads are effectively powered by a 48V battery charged by a powerful 48V generator, similar to a hybrid vehicle. This method can recover energy during load reduction and utilize internal combustion engine power in a more efficient manner.

Why hybrid electrification?Three-phase motor drive architecture source: ON Semiconductor
Figure 2. Three-phase motor drive architecture

The block diagram in Figure 2 also shows a typical three-phase motor drive architecture, where the choice of components depends on efficiency and power density requirements. In 48V applications, the power stage is based on 80V/100V MOSFET devices, which are properly designed to provide the required current to the motor. ON semiconductor offers a variety of first-class MOSFET solution combinations, these solutions have extremely low RDSON, excellent switching behavior and compact power package, such as NVMTS1D2N08H (80V, 337A, 1.1mΩ, TOLL package).

As an alternative to discrete implementation, ON Semiconductor provides an APM module platform that uses flexible, high-performance transfer molding packaging technology. In particular, APM19 uses first-class 80V/100V MOSFET technology to integrate a complete three-phase driver stage in a 40 x 25 mm package. It is the perfect solution to achieve the excellent thermal and electrical performance required for most critical power applications in the 48V domain. The power module based on the transfer-molded APM19 module platform complies with the AQG 324 standard.

Without the large investment of OEMs and Tier 1 suppliers, the 48V solution can solve the following applications:

・ 48V power generation and storage of auxiliary and hydraulic systems such as electric fan, electric turbine mode, electric working hydraulic pressure, electric AC compressor, electric slewing drive (excavator) and 48-12 DC-DC conversion
・ Water pump
・ Electric power steering system
・ Powertrain mild/hybrid

In order to complete the electrified products of various levels of engineering vehicles, a variety of auxiliary functions are provided, such as current detection amplifiers and gate driver product series. The tasks of this type of machinery require high reliability, robustness and longevity without sacrificing scalability and compact design. ON Semiconductor’s innovative and automotive certification solutions can meet the challenges of this market segment.

The Links:   LM64P10 6MBI50F-060

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