Electronic Motion Systems offers a variety of customized voltage regulators, rectifiers and inverters for current alternators as well as new starter alternator designs.
Automotive electrical loads continue to increase rapidly as new safety, comfort and entertainment features are added to the car. Furthermore, higher fuel efficiency, reliability and enhanced driving experience lead the electrification of formerly hydraulic and beltdriven systems, creating yet unprecedented electrical power levels and power system complexities in the car.
Electronic Motion Systems offers an array of technologies and processes to meet the customer’s requirements for today’s and next generation high power designs. We are the first to manufacture a production alternator active integrated rectifier regulator. We are prepared to address both 14V and 42V system requirements.
ALTERNATOR POWER MODULES
·Stand-Alone Voltage Regulators
·ECU-Controlled Voltage Regulators
·Integrated Rectifier Regulators
·Active Integrated Rectifier Regulators
·Reverse Alternator Power Modules
·Integrated Starter-Alternator Power Modules
PCM controlled alternator voltage regulator
FEATURES AT A GLANCE
- Thick film technology
- High current capability up to 600A
- Over-current and over-temperature protection
- Available 42V compatible solutions
- High volume production capability
- Bondable surfaces
- Active laser trimming of the circuit
- Passive laser trimming of resistors
THE Electronic Motion Systems ADVANTAGE
- Mechanical and electrical performances addressed at a system level
- Thermal design for under-the-hood capability: air flow and/or liquid cooling, severe thermal cycles
- Mechanical design for high reliability in an harsh environment: vibration, humidity, contaminants
- Very compact footprints
ALTERNATOR REGULATORS
For current alternator technology, Electronic Motion Systems offers customized voltage regulators as well as intelligent regulators integrating analog or digital communication with the engine control unit (ECU). The newer ECU-controlled regulators enable intelligent battery charging, increase battery life and provide better idle stability, diagnostic functions and acceleration-assist function using wide open throttle. Intelligent power management is an easy solution to get more power out of your current alternator technology with a minimum amount of risk.
Electronic Motion Systems regulators are designed for high reliability and can be configured to support various regulation features such as standard regulation, external temperature sense or load response control for smooth regulation during rapid load changes.
Communication protocols can be implemented to facilitate communication between the regulator and the engine control unit (ECU) or the body control module.
The communication strategies can be set up in self-synchronizing mode for simpler and more stable operation. Advanced communication protocols such as LIN can be provided to be compatible if a system network has been implemented.
Our customized voltage regulators are designed to integrate seamlessly into your alternator design to minimize assembly steps in high volume production as well as to provide very compact system solutions.
FEATURES AT A GLANCE
- Standard or ECU-controlled regulation
- Load response control
- Soft start
- Additional drivers for lamp or relay
- Battery sensing
- Fully protected
- Voltage set-point adjustment
- External temperature sense
- Air-cooled or water-cooled
- +25% more power with Active Integrated Rectifier Regulator
The demand for increased power generation in cars is creating the need for active rectification to dramatically reduce power losses. Active rectification has been discussed for a long time, but only recently has the development in advanced FETs made the concept feasible. The performance of active rectifiers with state-of-the-art FETs offers a large benefit with standard alternators manufactured today, with up to 25% more output power at idle speed. Selecting an active integrated rectifier regulator significantly reduces the amount of investment necessary to bring a higher power systems to market. Auto SBU manufactures the first AIRR in production today delivering up to 200A output current at idle speed and 320A at high RPM and can withstand 525A for 20s.
The AIRR combines a regulator with an active rectifier in one and the same module. On a simple level, active rectification is just the replacement of passive diodes with active power MOSFETs. The rectifier consists of a patent-pending transistor bridge rectifier concept, which can be adapted to customer specific designs to allow for better performance, higher efficiency, and an improved reliability over conventional solutions.
Features include synchronous operation, load dump strategy for a centralized suppression, and controlled regulation including communication exchange with the engine control unit. The configuration can be adapted to suit delta-wound as well as wye-wound generator configurations.
The trend towards increased integration of electrical and mechanical functions in today’s automobiles has led to the development of “reverse alternators” or integrated starter generators (ISG)/integrated starter alternators (ISA). The ISG/ISA combines starter and alternator functions into one compact system, allowing for start-stop strategies, brake regeneration, and power assist/boost. Starter-alternators makes it feasible to significantly increase the power generation capability of the engine and require specialized power systems.
The starter-alternator power stage employs a controlled three-phase MOSFET bridge that can be used to rectify the generated AC current as well as generate from a DC bus, three-phase current in an inverter mode to convert the generator to a starter motor. The multifunction power stage is controlled by a controller board, which sets the motor and generator modes to drive the power stage accordingly.
IR designs both the power and the control solutions to meet the customers’ 14V or 42V system requirements. Our designs closely integrate the M O S F E Ts with the drivers for optimum performance. The controller board includes multiple diagnostic and fail-safe functions. The circuit is optimized for high efficiency, with a low inductance pin-out.
Packaging is optimized for low thermal resistance, providing enhanced reliability in high temperature environment and compact footprint. Special interconnection technology is used for high current handling. A 42V to 14V DC-DC converter can also be integrated into the system if required.
