Cutting-Edge Power Technologies: Hands-On Laboratory Experience
Steve Rogerson Explores Rohm Semiconductor’s New European Power Lab
With automotive electronics getting more complex and market pressures rising, the job of an automotive electronics engineer is tougher than ever. Semiconductors are now used in such a wide range of applications that traditional datasheets no longer cover every possible scenario. This forces car manufacturers and their suppliers to collaborate more closely with component makers during the design phase.
Understanding these challenges, the Japanese firm Rohm Semiconductor launched its Power Lab at its European headquarters in Willich, near Dusseldorf, Germany, late last year. The lab aims to solve these issues by offering advanced testing and support.
“Engineers face numerous challenges today,” explains Aly Mashaly, manager for power systems at Rohm Semiconductor. “Designing circuits has become more complex with limited resources and tight deadlines. Engineers need better data and evaluation boards because they don’t have time to test new devices.”
One major issue engineers grapple with is thermal management, a field where the gap between datasheet information and real-world application becomes evident. “Datasheets can’t cover every application,” Mashaly mentions. “Different applications have varying loads and environmental conditions, and power semiconductors are used globally, so grid performance has to be factored in.”
To address these challenges, Rohm decided to offer specialized technical support locally in Europe, thus establishing the Power Lab. Engineers at the lab analyze how customers use the devices and provide support throughout the product lifecycle, focusing on system-level, not just component-level, integration.
“With the Power Lab, we can conduct special tests for customers at the application level,” Mashaly says. “We can demonstrate how different parts work together.”
The 300m² lab is equipped with advanced test benches and a high-voltage area to analyze power components and systems. “We’ve set up test benches using cutting-edge technology,” Mashaly notes.
The power test bench can perform tests on various converters (AC-DC, DC-DC, DC-AC, and AC-AC) in real-world conditions up to 15kVA. It also allows for precise efficiency measurements using power analyzers. Among its features are an AC power supply (grid emulator) and AC and DC electronic loads, with maximum voltages of 1500V DC and 400V AC.
Another key feature is the calorimetric test bench, used to study the thermal behavior of power devices and systems. It supports high current supplies, up to hundreds of amps, and includes a climatic chamber for temperature tests ranging from -40 to +180˚C, with humidity settings between 10% and 98%.
High-voltage tests up to 8kV are performed in a separate room for safety. The lab can also test insulation distances, known as clearance and creepage distances, up to 6kV at both the board and system levels.
“We designed the test benches ourselves,” Mashaly adds. “This guarantees quality and makes future modifications easier.”
Real-World Applications: Formula E
One company that has benefited from Rohm’s collaborative approach is the Formula E team Venturi. Being the team’s official technology partner since the 2016-17 season, Rohm’s silicon carbide (SiC) power devices have significantly enhanced the efficiency of the team’s power electronics.
“We are pushing all the components,” Mashaly says, summarizing Rohm’s commitment to innovation and customer support.
