**DC-DC Converter (1): Improving Voltage Conversion Efficiency**
TDK has started offering "DC-DC converters" for hybrid and electric vehicles. These vehicles often use batteries with voltages reaching hundreds of volts, and the DC-DC converter is responsible for reducing this voltage to 14V, which is then supplied to the lead-acid battery. This battery powers auxiliary systems such as the engine, wipers, and headlights.
The world’s first mass-produced hybrid car has been in use for over a decade, and the power density of DC-DC converters has steadily increased since then. TDK’s DC-DC converter was first used in hybrid vehicles as early as 1997. It is currently used in the Honda Civic Hybrid and the new Insight, as well as by several overseas manufacturers.
One of the key reasons Honda chose TDK's DC-DC converter is its compact size and lightweight design. By minimizing the size of the PCU (Power Control Unit) and Ni-MH batteries, Honda was able to free up more space in the vehicle, particularly in the luggage compartment. The miniaturization of the DC-DC converter not only enhances passenger space but also helps reduce manufacturing costs.
The latest DC-DC converters used in the Insight are 45% lighter and 5% smaller than those in the Civic Hybrid. They weigh less than 1kg and maintain a conversion efficiency of over 90%.
By eliminating the need for an alternator, hybrid and electric vehicles can rely on the DC-DC converter to charge the lead-acid battery. This reduces the number of components and improves overall efficiency.
In electric vehicles, where the battery capacity is significantly larger, the DC-DC converter plays a crucial role in charging the lead-acid battery, allowing the vehicle to function without an alternator.
The Insight model does not include an alternator, which further demonstrates the effectiveness of the DC-DC converter. With the rechargeable battery and DC-DC converter, the vehicle can supply power regardless of engine speed, ensuring consistent performance even under demanding conditions.
**DC-DC Converter (2): Retaining Lead Storage Battery**
Although hybrid and electric vehicles may seem to eliminate the need for lead storage batteries, they are still retained for important reasons. The Insight, for example, includes a lead battery. One major reason is cost reduction—lead batteries are much cheaper than rechargeable ones, making them a practical choice for certain functions.
Another key reason is redundancy. Lead batteries can deliver high currents quickly, which is essential for systems like air conditioning, wipers, and lights. If these systems were powered directly by the rechargeable battery, the DC-DC converter would need to be larger, increasing costs.
Additionally, the lead battery acts as a backup power source. In case the DC-DC converter fails, the lead battery ensures that critical systems remain operational, preventing a complete loss of power during driving.
Future improvements in DC-DC converters include bidirectional functionality, allowing power to flow both ways between the rechargeable and lead batteries. This will enhance system reliability and provide emergency power when needed.
TDK has developed various generations of DC-DC converters, including GEN3, GEN4, and GEN4.5, each improving upon the last in terms of efficiency and performance. The upcoming GEN5 is expected to achieve conversion efficiencies exceeding 90%.
Each generation of DC-DC converter is tailored to meet specific vehicle requirements, with designs adapted for cooling methods, terminal positions, and physical dimensions. The basic circuit structure is designed to operate reliably in harsh environments.
As technology continues to evolve, the role of the DC-DC converter in hybrid and electric vehicles will become even more critical, driving innovation and improving overall system performance.
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