Electric Vehicle News

Understanding AEC-Q200 Revision E qualified fuses for automotive electronics and EV applications

On March 20, 2023, the Automotive Electronics Council (AEC), the standards body for automotive electronic components, published Rev E of AEC-Q200, Stress Test Qualifications for Passive Electrical Devices. The new AEC-Q200 Revision E standard adds fuses to the list of components that can be AEC-Q200-qualified so that the fuses meet a high standard for ruggedness and reliability. Revision E provides a single standard that manufacturers can use to design and test fuses for the automotive market. The fuses must meet a rigorous set of more thorough tests that apply more significant stress than the tests required by standards for fuses from nationally recognized test laboratories such as UL and CSA.

The standards define the compliance requirements that qualify components that can withstand both the harsh automotive environment and extremes in the external environment. The components must pass environmental stress tests such as temperature cycling and humidity. In addition, the components must pass physical stress tests such as shock and vibration.

Littelfuse is the first automotive fuse manufacturer to introduce multiple AEC-Q200 Revision E-qualified fuses, including cartridge fuses, surface mount thin film chip fuses, high current surface mount fuses, and ceramic, fast-acting leaded fuses. View the video.

Needs for fuses in automotive vehicle circuits

The addition of electronics technologies into automotive vehicles has been extensive and is continuing. The substantial quantity of electronic circuitry requires individual overcurrent protection in each circuit.  Fuses are needed to protect the battery monitoring system (BMS), the on-board charger (OBC), the power distribution unit (PDU), the traction motor inverter, the communication circuits, and the vision circuits. Figure 1 shows the wide range of circuits in electric vehicles and lists the types of fuses needed for these circuits.

 

Figure 1. Applications for AEC-Q200 Rev E qualified fuses


AEQ-Q200 Rev E Test Standards

Figure 2 (top) describes the types of tests that the AEC-Q200 standard requires components to pass. The tests fall into two categories: environmental stress and physical characteristic stress. The environmental stress tests involve testing at high temperatures, cycling the fuse through a wide temperature range, and testing at high humidity.  The physical stress tests include mechanical shock, vibration, flammability, resistance to solvents, strength of the fuse terminals, and withstanding the heat from soldering. 

Figure 2. AEC-Q200 Revision E Tests

 

Figure 2 (bottom) gives examples of the AEC-Q200 Revision E stress tests that exceed the requirements of typical fuse test plans. In some cases, the typical test plan does not even include an AEC-Q200 Revision E test. In other cases, the new AEC-Q200 Revision E test has a 2x to 10x more difficult requirement than a typical fuse test.


Littelfuse AEC-Q200 Revision E Qualified Fuses

Littelfuse has a complete portfolio of AEC-Q200 Revision E-qualified fuses. The portfolio includes cartridge fuses, surface mount fuses, and ceramic fuses. 

Figure 3. Littelfuse AEC-Q200 Revision E Qualified Fuses Portfolio

Cartridge fuses

The 526 series, 527 series, and 828 series cartridge fuses shown in Figure 3 (top) have current ratings from 15 A to 60 A, with 500 V and 1000 V voltage ratings. The fuses have interrupting ratings of 10 kA and can operate in a temperature range from -55° C to +125° C. They have end caps with integrated stand-off leads or bolt-down options to eliminate the need for mounting accessories or lead-forming processes. These fuses can provide overcurrent protection for on-board charger circuits and the power distribution unit. 


Surface mount fuses

Littelfuse has an extensive line of AEC-Q200 Revision E surface mount fuses. The 885 series and 881 series fuses shown in Figure 3 (middle) can operate in high-voltage circuits with 100 V and 500 V ratings. The 881 series fuses have current ratings up to 100 A. Both series have an interrupting rating of 1500 A. These compact fuses can protect Li-ion battery modules in battery packs. 

An additional eight families of surface mount fuses are also shown in Figure 3 (bottom). These space-saving fuses have current ratings from 0.25 A to 20 A. The fuses can operate in circuits with voltages up to 250 V. Their operating temperature range, -55° C to 150° C, is the highest of all the AEC-Q200 Revision E fuse families. Use the surface mount fuse families in a wide range of automotive circuits, including the battery management system, the high voltage DC-DC converter, the automotive navigation system, the sensor circuits, the thin-film transistor display system, and the entertainment systems. 

Ceramic fuses

The PICO® II 521 ceramic fuses are a very fast-acting fuse series. They have current ratings between 2 A and 7 A. The 75 V rating allows use in circuits that operate up to that voltage. These fuses will interrupt a 200% overcurrent in 1 a maximum of 1 second. They can interrupt an overload up to 300 A. The 8 mm long x 3.4 wide body saves printed circuit board space and can perform over the -55° C to +125° C temperature range.  The PICO II 521 fuses can provide overcurrent protection for battery management system electronics and wire harnesses.

Most extensive portfolio of AEC-Q200 Revision E qualified fuses

Littelfuse has a broad fuses portfolio that is AEC-Q200 Revision E qualified for the automotive market. With current ratings from 2 A to 100 A and voltage ratings to 1000 V, Littelfuse has rugged, reliable, stress-tested fuse for every automotive application. Automotive designers can reduce qualification time for meeting the new requirements of the AEC-Q200 Revision E standard, and they can quickly identify Littelfuse overcurrent protection fuses to meet all their requirements.

For more information, visit the AEC-Q200 Revision E Qualified Fuses page and Updated AEC-Q200 Specifications for Automotive Applications presentation at Littelfuse.com.

For a quick introduction to the AEC-Q200 fuse portfolio, view the video. 

Learn more:

Source: Electric Vehicles Magazine

Stellantis and Saft unveil EV battery modules with integrated inverter and charger

Greater integration of EV components can deliver increased cargo space, simplified manufacturing and lower costs. Now Stellantis and Saft engineers have unveiled a prototype of an EV battery pack that integrates the inverter and charger functions into the modules.

The collaborative research project has produced the Intelligent Battery Integrated System (IBIS), in which the electronic conversion boards that perform the power inverter and charger functions are mounted as close as possible to the lithium-ion battery cells.

A demonstrator, operational since summer 2022, is the subject of numerous patents, and has enabled the companies to validate many new technical concepts. The IBIS project partners are now focused on building a fully functional prototype vehicle that will be tested on Stellantis development benches and test tracks as well as on open roads. The IBIS project team hopes to make this technology available on Stellantis vehicles before the end of this decade.

“Our journey to electrification is fueled by innovation and research excellence that uses the latest technology to address the real needs of our EV customers such as range, roominess and affordability, while reducing carbon footprint by improving efficiency,” said Ned Curic, Stellantis Chief Engineering and Technology Officer.

“Saft has been at the heart of industrial battery innovation for over 100 years,” said Saft CEO Cedric Duclos. “As pioneers in this cutting-edge field, our researchers are able to carry out research programs like IBIS over the long term.”

Source: Stellantis

Source: Electric Vehicles Magazine

New video details PepsiCo’s implementation of Tesla Semi electric trucks

“If you thought Tesla Semis were a bit like Bigfoot—maybe you heard about them, maybe you saw a fuzzy picture, but you weren’t sure if they were real or not—they are real, and they’re hauling real beverages here in Northern California.”

So says Mike Roeth, Executive Director of the North American Council for Freight Efficiency, to kick off a new video about PepsiCo’s fleet of Tesla Semis.

Like Bigfoot, the Tesla Semi is a seldom-seen species. Unlike the crypto-humanoid, the Semi definitely exists (and here’s the video to prove it!). However, Tesla has only delivered a limited number so far, and most of them are believed to be in operation in PepsiCo’s fleet.

At a logistics center near Sacramento, PepsiCo operates 21 Tesla Semis, along with four 750 kW Megachargers, which enable charging to 80% capacity in less than 45 minutes. PepsiCo also operates Ford and BYD EVs at the site, which gets much of its power from a solar array.

Anyone interested in fleet electrification should watch this video in its entirety—it includes an interesting discussion of the complexity of deploying sufficient charging power at a fleet depot. Two officials from the Sacramento Municipal Utility District (SMUD) explain the process, which involved bringing 3 MW of new electrical service to the facility, and took three years.

Dejan Antunovic, Electrification Program Manager at PepsiCo, explains that most of his company’s Tesla Semis are used for deliveries within 100 miles, and operate for up to 12 hours a day. However, three of the Semis serve routes that vary between 250 and 450 miles. “We have been aggressive to push the limit, and demonstrate that we are able to achieve a very high range with a fully-loaded tractor,” says he.

Mr. Antunovic says PepsiCo has achieved average efficiency of 1.7 kWh per mile with the Tesla Semi. According to Electrek’s calculations, that works out to an impressive 23% fuel cost reduction over the most efficient diesel trucks (assuming an energy cost of $0.14 per kWh, the current off-peak rate in Sacramento).

“This is a very big deal,” says Charles Burton, Director of Fleet Operations for PepsiCo’s North America West Division. “This is going to revolutionize how the trucking industry goes to market in the future.”

Source: North American Council for Freight Efficiency via Electrek

Source: Electric Vehicles Magazine

BMW Group to build new battery assembly factory in South Carolina

The BMW Group has broken ground for a new high-voltage battery assembly plant in Woodruff, South Carolina. Plant Woodruff will produce sixth-generation batteries to supply EVs at nearby BMW Manufacturing in Spartanburg.

Back in October 2022, BMW Group announced a new $1.7-billion investment in its US operations, including $1 billion to prepare Plant Spartanburg for the production of EVs and $700 million to build a new high-voltage battery assembly plant. The Woodruff facility will be about 100 acres in size.

The site will be operated without fossil fuels and will use 100% green electricity, the company said. The BMW Group has set itself the goal of reducing CO2 emissions in its global production network by 80% by 2030 from 2019.

“Our new battery assembly plant in Woodruff will soon play an important role in our electric future here in the USA,” said Ilka Horstmeier, member of the board of management of BMW.

Source: BMW Group

Source: Electric Vehicles Magazine

Electric Power Systems to provide aviation battery system for Elfly’s electric seaplane demonstrator  

The Norway-based Elfly Group is building an electric amphibious aircraft, inspired by the venerable de Havilland Twin Otter and Grumman’s Mallard. The Noemi seaplane is designed for 200-kilometer air journeys, and will be powered by two electric motors with up to 1 MW combined output. A prototype is expected to make its first flight in 2025.

Elfly has selected Electric Power Systems (EPS) as the battery provider for the electric seaplane. EPS will deliver its EPiC battery line for the initial demonstration.

Electric Power Systems has numerous battery systems currently powering demonstrator aircraft, including the NASA X-57, Bell Nexus, Aurora Pegasus, Embraer Ipanema and Boeing Cargo Air Vehicle. EPS has also partnered with the FAA to certify batteries for general aviation aircraft, and will complete its first Technical Standard Order this year.

“We are confident that our advanced battery technology will contribute significantly to the success of the project,” said Nathan Millecam, CEO of Electric Power Systems.

“EPS’s highly relevant experience supporting battery technology on complementary, innovative programs positions them well for our next-generation seaplane, which we intend to build and fly under our own Air Operator’s Certificate in Norway,” said Elfly CEO and founder Eric Lithun.

Source: Electric Power Systems

Source: Electric Vehicles Magazine

London electric waste-collection fleet is powered by waste it collects

Westminster City Council and French transnational water- and waste-management company Veolia have announced the rollout over the coming weeks of 45 new electric refuse collection trucks, which represents an investment of £20 million. Plans call for eventual replacement of the entire existing fleet of 80 trucks. According to estimates, each EV will reduce CO2 emissions by as much as 89% compared to a diesel-powered truck.

The vehicles are built by Dennis Eagle in Warwick. They will be charged at a new depot at Landmann Way that can simultaneously accommodate 54 trucks. An adjacent energy-recovery facility, South East London Combined Heat and Power, will provide the depot with 3.3 GWh of electricity annually. The facility treats residual waste, including that collected from homes and businesses in Westminster, to generate 265 GWh of electricity a year.

Westminster’s fleet performs 50 million collections a year. It is operated by Veolia, which procured, designed and will operate the new depot and charging infrastructure. “Using the waste we collect to power the electric fleet is an exciting innovation, because that creates a local loop of energy, using local resources to run local services,” said Pascal Hauret, Managing Director Veolia UK Municipal.

Source: City of Westminster

Source: Electric Vehicles Magazine