Wallentowitz • Amsel (Eds.) 42 V-PowerNets ONLINE LIBRARY Springer-Verlag Engineering Berlin http://www.springer.de/engine/ Heidelberg GmbH H. Wallentowitz • C. Amsel (Eds.) 42V-PowerNets With 168 Figures and 16 Tables Springer Editors: Prof. Dr.-Ing. Hennig Wallentowitz Dipl.-Ing. Christian Amsel RWTH Aachen Institut für Kraftfahrwesen (ika) Steinbachstr. 7 52074 Aachen, Germany E-mail: wallentowitz @ ika. rwth-aachen. de amsel @ ika. rwth-aachen. de ISBN 978-3-642-62104-8 ISBN 978-3-642-18139-9 (eBook) DOI 10.1007/978-3-642-18139-9 Cataloging-in-Publication Data applied for Bibliographic information published by Die Deutsche Bibliothek. Die Deutsche Bibliothek Hsts this pubHcation in the Deutsche Nationalbibliografie; detailed bibliographic data is available in the Internet at <http://dnb.ddb.de> This work is subject to copyright. 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Typesetting: Camera ready by authors Cover-design: Medio, Berlin Printed on acid-free paper 62 / 3020 hu - 5 4 3 2 1 o - Preface Preface to the Series EUROMOTOR is an advanced training program sponsored by the Euro- pean Union for engineers of the European automotive and supplier indus- try. Its aim is the exchange of experiences with new developments be- tween industry and university. Courses are offered in all fields around the automobile, as for example vehicle dynamics, vibration & ergonomics, powertrain, crashworthiness, manufacturing, aerodynamics, testing and fa- tigue as well as courses in the field of body engineering and electronics. For further information, please contact: EUROMOTOR Support Office, Caroline Marshall, RSBD, University of Birmingham, Birmingham B15 2TT, UK, Tel: +44 (0) 121 414 3695, Fax: +44 (0) 121 414 7151, e-mail: [email protected]. Preface to this volume On June 17th and 18th, the EUROMOTOR Course “1st Aachener Elec- tronics Symposium" took place at the Institut für Kraftfahrwesen (ika) in Aachen/Germany. The conference dealt with the main topic "Fusing Strategies for Future Vehicle PowerNets". Speakers and participants from the automotive and supplier industry as well as research institutes reported the latest developments and trends in the field of fusing strategies. Technical experts in the field of active and passive fuses as well as systems suppliers presented special methods for the solution of the partial and overall problems. Intensive discussions about the technical aspects that have to be considered when introducing the new 42V-PowerNet into automobiles took place. The event was organized for a limited number of participants. For each presentation a time limit of 30 minutes with additional 15 minutes for a following discussion was set. We hope that this compilation provides the reader with a well-balanced overview of the problems associated with guaranteeing the safety of future vehicle powernets. In order to ensure a continuous exchange of technol- ogy, this symposium is planned to be held every two years. VI Our sincere thanks go out to the contributors for their eagerness to pre- sent the state-of-the-art technology from their organisations and for allow- ing their articles to be published in this volume. Aachen, 2003 Prof. Dr.-Ing. Henning Wallentowitz Dipl.-Ing. Christian Amsel VII List of authors Amsel, Christian Forschungsgesellschaft Kraftfahrwesen mbH, Aachen, Germany Bellew, Patrick Littlefuse Ltd, Dundalk, Ireland Borrego, Carles Lear Corporation, Valls, Spain Brinkmeyer; Horst DaimlerChrysler, Sindelfingen, Germany Edmund, Erich Delphi, Wuppertal, Germany Figuerola, Gabriel Lear Corporation, Valls, Spain Fischer, Roland DaimlerChrysler, Frankfurt, Germany Fontanilles, Joan Lear Corporation, Valls, Spain Graf, Volker Intedis & Co. KG Gresch, Peter Adam Opel AG, ITDC-PE Electronics, Rüsselsheim, Germany Gretzke, Werner Tyco Electronics Raychem GmbH, Ottobrunn Große, Ronald Forschungsgesellschaft Kraftfahrwesen mbH, Aachen, Germany Hinrichs, Werner PUDENZ GmbH, 27243 Dünsen, Germany VIII Jasper, Jo Litlefuse BV, Utrecht, Netherlands Kroeker, Matthias Tyco ElectronicsAMP GmbH, 13629 Berlin, Germany Mäckel, Rainer, DaimlerChrysler, Frankfurt, Germany McLoughlin Littlefuse Ltd, Dundalk, Ireland Mestre, Jordi Lear Corporation, Valls, Spain Niebler, Erich Vishay Electronic GmbH, Selb O’Shea, Paddy Vishay Intertechnology Inc., Ireland Pohl, Klaus Dieter Universität-Gesamthochschule Wuppertal, Germany Seyer, Reinhard DaimlerChrysler, Frankfurt, Germany Scheele, Jürgen PUDENZ GmbH, 27243 Dünsen, Germany Schmidt, Fritz DaimlerChrysler, Sindelfingen, Germany Schulz, Thomas DaimlerChrysler, Sindelfingen, Germany Zörn, Ronald PUDENZ GmbH, 27243 Dünsen, Germany IX Contents Introduction………………………………………………………..… XIII 42V-PowerNet: Status of Development, Requirements and Perspective……………….. 1 Peter Gresch 1 Introduction………………………………………………………………………1 2 Reasons………………………………………………………………………….. 3 3 Benefits………………………………………………………………………….. 3 4 Challenges………………………………………………………………………. 7 5 Introduction Scenario………………………………………………………….. 10 6 Conclusions……………………………………………..……………………... 12 7 References……………………………………………..……………..………... 14 Cable Fire in Automobiles: Causes, Effects and Prevention……....… 15 Klaus Dieter Pohl 1 Introduction……………………………………………………………………. 15 2 Fire in Automobiles……………………………………………………………. 18 3 Cable Fire as a Source of Fires in Automobiles……………………………….. 21 4 Summary………………………………………………………………………. 38 Circuit protection components for future vehicle electrical systems…………………………………… 41 Jo Jaspar, Neil McLoughlin, Patrick Bellew 1 Introduction: Higher System Voltage, why and when?……………………….. 41 2 System Definition……………………………………………………………... 43 3 Most realistic Assumptions……………………………………………………. 55 4 Conclusions……………………………………………………………………. 71 5 References…………………………………………………………………..…. 72 Use of PolySwitch PPTC Protectionin Automotive Applications..….. 75 Werner Gretzke 1 PPTC Principle of Operation…………………………………………………... 76 2 Design Considerations for PPTC Devices……………………………………... 78 3 Applications for Resettable Circuit Protection in Automotive Electronics…… 81 4 Compliance with Industry Standards………………………………………….. 86 5 Summary………………………………………………………………………. 87 New Fusing Concept under Consideration of Wire Characteristics………………...…….… 89 Werner Hinrichs, Jürgen Scheele, Ronald Zörn X 1 Introduction......................................................................................................... 89 2 Fuse Protection in Automotive Applications………………………………….. 90 3 Definitions, Acronyms, Abbreviations………………………………………... 98 4 References……………………………………………………………………... 99 Overvoltage Protection Devices for the Automotive Power Network……………………………...…... 101 Paddy O´Shea, Erich Niebler 1 Introduction…………………………………………………………... 101 2 What is the Threat on 14 V/42 V Systems…………………………… 103 3 Load Dump Solutions………………………………………………… 103 4 Module Level Protection 12 V/14 V/42 V…………………………… 107 5 Electrostatic Discharge……………………………………………….. 110 6 Summary……………………………………………………………... 112 Power Switches for the 42V-PowerNet…………….…………..…….. 113 Solution for Power Net Protection and Applications Matthias Kroeker 1 Introduction…………………………………………………………………... 113 2 Switching 42 V Loads………………………………………………………... 115 3 References……………………………………………………………………. 133 Detection and Characterization of Short Circuits in 42V-PowerNets…..……………………………………………….… 135 Reinhard Seyer, Roland Fischer, Rainer Mäckel Horst Brinkmeyer, Fritz Schmidt, Thomas Schulz 1 Introduction....................................................................................................... 135 2 Short Circuits in 42V-PowerNets…………………………………………….. 136 3 Experimental Approach………………………………………………………. 139 4 Characterization of the Criticality……………………………………………. 141 5 Thermal Mode………………………………………………………………... 143 6 Detection of Short Circuits and Protection Concepts………………………… 144 7 References……………………………………………………………………. 145 Investigations of Electrical Failures in the Dual Voltage PowerNet.. 147 Ronald Große, Christian Amsel 1 Introduction…………………………………………………………………... 147 2 Concepts of Investigations of electrical Faults in Vehicle Electrical Systems.. 148 3 Summary……………………………………………………………………… 157 4 References……………………………………………………………………. 159 Protection Strategies for Future Electrical Vehicle Architectures: Towards Fuseless Strategies.................................................................. 159 Joan Fontanilles, Carles Borrego, Gabriel Figuerola, Jordi Mestre