Fraunhofer Institute for Integrated Systems and Device Technology IISBWe are specialized in top tier DC/DC converters: galvanically isolating, bidirectional, and single-stage. This enables us to offer solutions with high power density and a high power-to-weight ratio. Our developments are ideal for safety-relevant applications such as autonomous driving or electric flying. For current projects, we use our iisb² (integrated, galvanically insulated, separated buck/boost) circuit topology as the basis.
On-Board Converters
Demonstrator from the BMWi GETpower2 project
- HV voltage: 540 V to 840 V
- 12/24/48 V versions
- max. 11.2 kW / 400 A @ 28 V
- approx. 4 dm³ construction volume / approx. 7 kg.
- Design for aviation sector: e.g. factor 2 voltage reserve for HV SiC MOSFETs, increased clearance and creepage distances, special housing for protective glass filling
- Two input voltage and three output voltage versions for 12 V, 24 V or 48 V auxiliary power supply
- Full digital control
- Communication via CAN
- 85 °C max. coolant temperature
- The serial connectable phases on the primary side allow the use of cost efficient semiconductors with only 600 V blocking voltage up to 800 V DC-Link voltage
The customer-oriented on-board DC/DC converter has three independent bidirectional ports to connect all future available on-board grids: HV, 48 V and 12 V. With the converter, complex automotive on-board energy management tasks can be fulfilled, like boosting energy between the 48 V and 12 V grid, size reduction of the 12 V battery, replacement by supercaps or transferring energy between the high voltage grid and the low voltage grids. For safety reasons, the12 V as well as the 48 V port are galvanically isolated from the HV port. The converter can be fully controlled via CAN and is characterized by its extremely low height of just 49 mm. Due to the well chosen circuit topology and the advanced design and packaging, a very high power density is achieved for a converter with the described high functionality.
Features
- Three independent, bidirectional ports (HV, 48 V, 12 V)
- All three ports useable at the same time
- Galvanic isolation between HV and 48 V
- Galvanic isolation between HV and 12 V
- Wide input/output voltage ranges
- Over voltage / current protection / temperature control
- Voltage & current control modes for all ports
- High partial load efficiency through phase shedding
- CAN communication
- Water cooling
- High power density
- Ultra-low profile
- Without electrolytic capacitors
- Usable for different electric energy storages (LiIo-batteries, lead acid batteries, supercaps)
- Designed for complex automotive on-board energy management tasks
Competence Center »Green ICT @ FMD«
With the development of modern electronics for resource-saving information and communication technology, the Green ICT @ FMD competence center is contributing to the German government's climate goals.
In order to contribute to reducing the carbon footprint of digital technologies with R&D, the Fraunhofer and Leibniz Institutes cooperating in the Research Fab Microelectronics Germany (FMD) are jointly establishing a cross-location competence center for resource-conscious information and communication technology, the Green ICT @ FMD. The BMBF is supporting the project, which was launched on August 1, 2022, with funding of 34 million euros as part of the Green ICT initiative, which is part of the German government's 2030 climate protection program.
In Erlangen, Dresden and Berlin, new application- and system-oriented Green ICT hubs complement existing research activities at the FMD institutes and as a basis for further research work. The hubs offer project partners from industry and science the opportunity to evaluate systems and subsystems, demonstrators and prototypes in dedicated testbeds with regard to the special requirements for environmentally friendly products and, if necessary, to have them optimized. Fraunhofer IISB is participating in two of the Green ICT Hubs with the following activities:
Green-ICT Hub for Sensor Edge Cloud (SEC)
- Further development and optimization of energy-efficient DC/DC voltage converters for use in data centers
- Further development, optimization, implementation and use of sensor systems for the energy-efficient control of manufacturing processes
- Implementation and use of simulation and AI-supported optimization processes to increase energy and resource efficiency in semiconductor production
The Green ICT Hub for resource-optimized electronics production - Implementation and use of an integrated energy management system and establishment of intelligent operating strategies for the cleanroom energy infrastructure and for process plants along the supply chain exemplified by a process tool from the field of wet chemistry
- Use of artificial intelligence methods to increase compactness through optimal component placement e.g. on PCBs
- Optimization in the manufacturing of power electronic packages
- Replacing other metals with copper to improve the environmental balance in the production and recycling of power electronic junction structures
