Aluminum Electrolytic Capacitors for Automotive Applications
Product Profile 2005
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C O N T E N T S
Basic construction 4Technology and quality 5Applications 6
Large size s Introduction
8s Data sheet B41605 (140 °C, 2000 h)9s Data sheet B41607 (150 °C, 2000 h)
14
Axial-lead and soldering star s Introduction
18s Data sheet B41691/B41791 (150 °C, 2000 h)19s Data sheet B41692/B41792 (140 °C, 2000 h)23s Data sheet B41693/B41793 (150 °C, 1000 h)28s Data sheet B41694/B41794 (140 °C, 1000 h)32s Data sheet B41695/B41795 (150 °C, 1000 h)36s Data sheet B41696/B41796 (125 °C, 3000 h)41s Data sheet B43693/B43793 (125 °C, 2500 h)
45
Single-ended s Introduction
49s Data sheet B41853 (105 °C, 3000 h)50s Data sheet B41868 (150 °C, 1000 h)
52s Data sheet B41888 (105 °C, 4000 ... 10000 h)55s Data sheet B41896 (125 °C, 2000 ... 5000 h)58s Data sheet B43866 (125 °C, 2000 h)61s Overview of packing units 63s Lead configurations 63s Mounting considerations 67Important notes 68Cautions and warnings 69Symbols and terms
71
Properties
Electrical
s Operating temperature up to 150 °C s High ripple current capability s Long useful life s Low ESR
s
Low leakage current
Physical
s High C/V product s Compact design
s High vibration resistance s Easy mounting
s QC selected materials s PCB free
s
Non-toxic electrolyte
KAL0229-F-E
Tabs
Cathode foil
Paper
Anode foil
Paper
Projecting
Technology and quality
Technology
The aluminum oxide layer (Al2O3) on the surface of the anode foil acts as a dielectric between the anode and cathode. The dielectric strength of the capacitor depends on the thick-ness of the oxide layer – which in turn determines the maximum per-missible operating voltage (LV: low voltage; HV: high voltage). The sur-face of the anode foil increased by chemical treatment affects directly the capacitance (C).
Capacitors with this configuration have a polar design with positive and negative poles.
The materials used for them have
to meet strict purity requirements
and undergo special QC selection procedures. Electrolytes used by EPCOS do not contain solvents that are detrimental to health, such as
dimethyl formamide (DMF) or dimethyl acetamide (DMC). Improved electrolytes cover oper-ating temperatures up to 150°C.
Quality
Automotive electronics manufac-turers and vehicle manufacturers in particular insist that their suppliers have comprehensive QM systems
in place that are geared to total process mastery. These demands are reflected in international quality assurance standards such as ISO 9001 and the ISO/TS 16949 stan-dard derived from it with specific requirements of the automobile industry.
It is a principle of EPCOS' quality policy that the QM system must satisfy the most demanding inter-national standard applicable. Certification of the entire EPCOS Group was therefore tackled on the basis of ISO/TS 16949 in 2003 and completed in February 2004. The EPCOS QM system is constantly being reviewed and systematically refined within the company, because uncompromising quality also means a never-ending process of improve-ment.
Electromechanical brake (EMB)
The pedal travel sensor of the electromechanical brake system recognizes the braking command and informs the brake controller after an adjusted delay. The power elec-tronics controls the electric motors attached to the brakes mounted on each wheel. The brake is activated and deactivated by changing the direction of rotation of the motor (cw/ccw). A very fast direction
change capability and control mech-anism is required by a feature such as ABS.
Electrohydraulic brake (EHB)
Mechanical and hydraulic connec-tions have been replaced by electri-cally controlled functions. The pedal travel sensor of the electro-hydraulic brake system recognizes the driver‘s brake command and the control unit receives the braking signal. An adjusted braking power is then applied, depending on a stored brake characteristic which represents the relationship between brake movement, required braking power and speed.
A solenoid valve adjusts the brak-ing power to the right level. In case of electric power loss (emergency),braking is ensured by a direct
hydraulic link from the master brake cylinder to the brakes.
Direct unit injection system (DUI)
The DUI ensures extremely low emis-sion values in compression-ignition engines and meets the strict exhaust limits of the D4 level, set by the EU.A control board manages the high-pressure system, the amount of injected fuel and the accurate timing of the injection. Only components ensuring high operational reliability in a wide temperature range are suitable for this application.
Electromechanical brake Electrohydraulic brake Direct unit injection system (EMB)(EHB)(DUI)
KAL0664-S
Front Axle Rear Axle
Actuator
Actuator
Control Unit EMB Brake Pedal Module &Pedal Travel Sensor
42 V Power Supply & Back Up
5
54
4M
3
2
1
CAN
Power Supply Signal Interface
5Plunger Connector
4Backup Valve 3Master
Brake Cylinder
Brake
Operation Unit Sensor
Pedal Travel Sensor 21EHB Control Unit
Rear Axle
Front Axle S/U
P
P/U P/U
P/U P/U P/U P/U
KAL0663-J
Photos: Bosch
Meeting the typical stringent demands of customers in the automotive industry,
EPCOS aluminum electrolytic capacitors have been designed for applications such as:
Valvetronic (VVT)
The variable vent technique (VVT)bases on the well-known Double-Vanos system. An additional camshaft powered by an electric motor acts as a core allowing the fully-variable lift control of the intake valves to be adjusted. The motor action is controlled by the VVT con-troller. The short power burst is pro-vided by the aluminum electrolytic capacitor. This feature allows CO 2emissions to be drastically reduced as well as the gasoline consumption (gas mileage) to be improved.
Active front steering (AFS)
The active front steering is integrated into the steering rod. Its main parts are an electric actuator and an inte-grated planet-gear which operates
Photo: Siemens VDO Automotive AG
the angle sensor and activates the actuator – thus providing the power steering.
In the near future, an upgraded AFS version will no longer rely on mechanical steering commands and will implement a genuine “steer-by-wire” (SbW) system. A steering controller sends commands to an electric motor which responds by moving the steering gear and set-ting the front wheels into the right po-sition.
In future this feature will also allow programmed steering characteris-tics to be used as inputs (overlay)for automatic cruise control (load change in curve/yaw-rate regulation).
EPCOS provides the capacitors used in the above mentioned applications. Photo: Bosch
Large size
Aluminum electrolytic capacitors
Introduction
The B41605 and B41607 series were designed for applications with strin-gent demands for power and current carrying capacity at ambient temper-atures ranging up to 150 °C. Tinned copper leads of 1.2 mm diameter, al-so allowing determination of the poles because of the different lead length,can be either welded or soldered.To stand up the specified vibrational stability in an automobile, EPCOS developed a special process for these models, in the meantime patented,that fixes the capacitor winding so re-liably by a sophisticated corrugation configuration that vibrational stability up to 40g can be specified even for these large-sized models.
Up to 40 g vibration stability version Snap-in version
Large size capacitor, up to 40 g vibration stability version with wired terminals
Large size capacitor, snap-in version with 3 terminals
Technical data, case dimensions and ordering codes
*** = "002" for snap-in version with 3 terminals (protection against polarity reversal), fully insulated.
"009" for up to 40 g vibration stability version with wired terminals, fully insulated.
Large size capacitor, up to 40 g vibration stability version with wired terminals
Large size capacitor, snap-in version with 3 terminals
Technical data, case dimensions and ordering codes
*** = "002" for snap-in version with 3 terminals (protection against polarity reversal), fully insulated.
"009" for up to 40 g vibration stability version with wired terminals, fully insulated.
Axial-lead and soldering star Aluminum electrolytic capacitors
Introduction
Axial-lead (B4169x/B43693) and sol-
dering star (B4179x/B43793) capaci-
tors can withstand temperatures up
to 150 °C and vibrations up to 20 g.
They are specified for an extended
useful life, offer outstanding electrical
performance at high reliability and
can withstand temperature changes
specified according to the typical
automotive requirements.
The innovative “automotive grade se-
ries” combines high ripple current
load and very low ESR with a com-
pact design.
The winding element is fixed by the
corrugation in the middle of the can.
Tensile strain applied to the tabs by
vibration stress is eliminated by cor-
rugated tabs. The lead wire (? 1 mm)
withstands high mechanical stress.
Moreover, low ESR and an extended
useful life contribute to their high reli-
ability and performance. These new
series from EPCOS have been up-
graded to operating temperatures of
150 °C and are designed for typical
automotive customers’ specifications.
Soldering star aluminum electrolytic
capacitors (with a star connector
terminal) have a comparable internal
winding construction to the axial-lead
types. The center contact acts as the
positive pole and the capacitor case
as the negative pole. The star con-
nector terminal is welded to the case
and so also has negative polarity. A
simple mounting method (pick and
place) is an added advantage of this
design.
1mm wires and corrugation for increased vibration stability, enhanced further by soldering star design.
1)If optimum circuit design is used, the values are lower by 30%.
Axial-lead capacitors Soldering star capacitors
d = 14 mm
KAL0357-R d= 16 mm
KAL0358-Z
?
d = 18 mm
KAL0359-8
The PC board hole arrangement
specified above is based on circular arcs.
If, however, the mounting holes have to be matched to a stan-dard drilling raster, a spacing of 1.27mm (1/20? ) has proved to be sufficiently accurate if the