Safe, Highly Reliable Mobility with Automotive Electronics
Power grid stabilization in vehicles with various propulsion strategies
Automotive Electronics
The Electronics Expert for Safe and Stable Power Grids
Alternative drive concepts and safety aspects in autonomous driving are placing new demands on the power grid. The need for electrical power in the vehicle is continuously growing in order to guarantee extra safety and comfort for the occupants. At the same time, the electrification of drives or parts of the drive train allows CO2 emissions to be reduced. The extensive portfolio at Eberspächer includes solutions for all vehicle types, drive types and low-voltage currents. We have technological expertise in construction and connection technology, and in casting. From pre-development to series production and the aftermarket, everything is located under one roof. Even with an international scope, this allows for agile and flexible working methods. Our locations in Germany, the United States, and China guarantee close proximity to our clients.
Eberspächer Automotive Electronics develops and produces electronic modules and systems for the reliable operation of the vehicle power grid up to Autonomous Driving Level 5. Our components deliver the electrical power in the power grid precisely where it is needed. Eberspächer Automotive Electronics has produced more than 40 million modules in the last 20 years.
Modules Based on Semiconductors – Keeping High Currents under Control
Highly safe, intelligent switch solutions such as voltage drop limiters or e-relays are needed to reliably switch high currents and distribute them in the vehicle. We rely on efficient semiconductor technology in our modules and cooperate directly with manufacturers. This allows us to offer solutions for various low-voltage levels to clients around the world. The fast switching speeds enable the safe operation of the vehicle. Over 200 million MOSFETs have already been fitted by the Eberspächer experts so far. Our method of molding high-power bus bars is patented. Thanks to our know-how, we can reduce power loss and require less installation space. Our expertise makes us a reliable partner.
From a physical point of view, a high current relay – also known as a solid state relay (SSR) – is a switching device that automatically closes or opens a series of contacts between two circuits. In vehicles of all kinds, whether conventional combustion engines, plug-in hybrids or battery electric vehicles (BEV), high current relays are used for safe power distribution in the vehicle power grid. Highly safe and intelligent switch solutions reliably switch even high currents – with low energy requirements, high current carrying capacity and extremely fast switching times.
Solid state relays score points for their durability: they achieve a very large number of wear-free switching cycles. This long service life distinguishes them from mechanical relays, as the current flow is controlled by electronic circuits and not by mechanical contacts – wear is therefore excluded. This makes Eberspächer high current power switches indispensable for use in safety-critical functions in modern vehicles.
High current relays are used in all kinds of industrial applications. In the automotive industry, a wide range of modern assistance and safety systems require the use of solid state relays: they enable the protection of critical components such as X-by-wire systems and are essential for the implementation of modern vehicle functions such as traffic jam pilots. In emergency situations, solid state relays ensure the short-term supply of energy, for example to temporarily maintain the exterior lighting of a vehicle. Due to the very high functional safety requirements, high current power switches are indispensable in autonomous driving. Every assistance system used must be supplied with the appropriate energy – solid state relays stabilize the vehicle power grid and enable the smooth functionality of electronic driving systems.
Whether combustion, hybrid or electric vehicle: applications are safety-critical functions in the low voltage range below 60 Volt. Eberspächer offers solid state relays for a voltage of 12, 24 or 48 Volt. Especially in the low voltage range, SSRs are the most efficient method for switching high currents, which are prevalent in complex applications. The Eberspächer Automotive Electronics portfolio includes single-channel as well as multi-channel power distributors to reliably cover customer-specific requirements in the automotive sector through to applications for autonomous driving up to level 5.
Supercap Modules as secure Energy Storage
Whether as 12 V or 48 V variants, our supercapacitor modules serve as reliable power storages. They are used within vehicles of all drivetrain types to stabilize the energy supply. Especially in battery electric vehicles, modern power grids demand for high energy flows and increasing safety requirements due to their complexity. As integrated solutions, Eberspächer supercapacitor modules, short SCAP- or UCAP modules, guarantee the supply of the vehicle power grid as well as critical electrical consumers in case of an emergency. These include, for example, electronic braking and steering systems (X-by-Wire). As buffer storage units, they also stabilize the power grid to compensate current peaks. Our 48 V supercapacitor storage is used as standard by leading manufacturers: to store braking energy in electric and hybrid vehicles or as power supply for roll stabilizers. The reliable 12 V power storages of Eberspächer are used as a redundant energy source. In autonomous driving, for example, supercap modules ensure the secure operation of the vehicle power grid.
The expertise of Eberspächer Automotive Electronics can be seen in particular in the area of system and software integration as well as the development of diagnosis functions for supercapacitor modules. These include state-of-charge (SOC), state-of-health (SOH), and state-of-function (SOF).
Pronounced Manufacturing Expertise for Diverse Applications
Our efficient manufacturing techniques and methods are valued by our clients around the world. To cast the modules, we employ a patented method to provide a seal and dissipate heat. Agile project methods, team spirit, a young, dynamic and familial working environment as well as quick decision processes characterize our targeted approach to our work. This sets us apart as a reliable partner for our international clients. We develop and produce solutions for a wide range of vehicle types, different drive types, and low-voltage levels – from low-cost to high-end products.
Our product innovations
High-performance switches – small and compact
POWERSENTINEL
The PowerSentinel – Advanced Switching Solution (PASS) power switch developed by Eberspächer implements the intelligent and highly secure energy supply in modern on-board electrical systems. This technology is used primarily in the supply of safety-related driving functions. The PowerSentinel protects safety functions from voltage-related failures.
Press release
Safety for the lithium-ion starter battery
12 V BATTERY MANAGEMENT SYSTEM
The automation of a wide range of functions and the trend towards electrification are increasing the complexity of electronic vehicle architecture. The 12 V battery management system from Eberspächer ensures the necessary safety of automated driving functions. The automotive electronics recognize the battery status via the connection to the vehicle power grid.
Press release
Active on-board power supply management
POWER DISTRIBUTION MODULE
In autonomously driving vehicles, the redundant design of on-board power grids ensures the greatest possible security of supply. With its power distribution module, Eberspächer provides a solution for the safe distribution of energy and intelligent monitoring of the low-voltage grid – customized for each individual customer. It thus actively contributes to autonomous driving at level 5.
Low power, big impact
DC/DC CONVERTERS
High power is also required in 12 V topologies for specific applications, such as for de-icing or to prevent the windshield from fogging up. As an expert in low-voltage DC/DC converters, Eberspächer offers a highly efficient and variable solution from 32 V to 52 V for various applications. They impress with their low weight and good EMC shielding.
Semiconductor-based relays for a long service life
ELECTRONIC RELAYS
As an expert in semiconductor-based switches, Eberspächer offers electronic relays in a range of variants for high currents (>100 A), some of which are fully compatible with electromechanical relays. E-relays are characterized by a smaller required space and significantly lower weight. The reduced power loss also results in lower heat emission. Compared to conventional relays, semiconductor-based relays have a significantly longer service life.
Energy storage for increased safety
SUPERCAP MODULES
Conventional batteries are subject to an aging process: they lose capacity over their lifespan. In addition, they are heavy and are not able to absorb or release energy quickly. Supercap modules offer a viable alternative: they are suitable as a back-up energy source for x-by-wire applications, in particular for steering. SCAPs are also an optimized solution as a starting aid in hybrid vehicles or in electronic roll stabilization.
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