Author Topic: Renault Zoe EV Power Electronics Block teardown  (Read 509 times)

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Offline mikeselectricstuff

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Renault Zoe EV Power Electronics Block teardown
« on: February 26, 2020, 09:17:01 pm »
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Online Gyro

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Re: Renault Zoe EV Power Electronics Block teardown
« Reply #1 on: February 27, 2020, 06:56:15 pm »
Nice teardown. Both impressive and rather scary!

Ok, the control stuff is fairly normal smt, but those bare die power modules are really scary - how on earth do they manage to reliably bond those multiple heavy bond wires to the thin surface metallisation on the dies?  :o.  They also seem to have relatively little surface area exposed to the coolant flow. All in all, quite a large number of coolant seals and internal connectors.

I'm glad my Niro has a nice long warranty! - 32kW main motor, 8kW hybrid starter-generator for the engine, and Aircon compressor, all high voltage three phase brushless, and running off the same inverter module.
« Last Edit: February 27, 2020, 07:01:19 pm by Gyro »
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Offline f4eru

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Re: Renault Zoe EV Power Electronics Block teardown
« Reply #2 on: February 27, 2020, 08:39:03 pm »
Yes, true.
It's a first gen, so it could be simpler today.

Those seals are hopefully silicone, so they don't harden over time.
The pressure and temp in this coolant are not as extreme as in an ICE.

Also, I find the choice of passive rectification bizarre for a 12V/80A PSU. Yeah, the design is quite old. Today, the DCDC at least would probably be made very differently, when we see the huge evolution of power devices
« Last Edit: February 27, 2020, 08:42:05 pm by f4eru »
 

Offline ahbushnell

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Re: Renault Zoe EV Power Electronics Block teardown
« Reply #3 on: February 28, 2020, 02:14:11 am »
Nice teardown. Both impressive and rather scary!

Ok, the control stuff is fairly normal smt, but those bare die power modules are really scary - how on earth do they manage to reliably bond those multiple heavy bond wires to the thin surface metallisation on the dies?  :o.  They also seem to have relatively little surface area exposed to the coolant flow. All in all, quite a large number of coolant seals and internal connectors.

I'm glad my Niro has a nice long warranty! - 32kW main motor, 8kW hybrid starter-generator for the engine, and Aircon compressor, all high voltage three phase brushless, and running off the same inverter module.

The wire bonding on the IGBT's is standard construction that's been around a long time.  The sticky stuff we call snot.  It's a silicone compound. 

 

Online Gyro

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Re: Renault Zoe EV Power Electronics Block teardown
« Reply #4 on: February 28, 2020, 10:02:59 am »
The wire bonding on the IGBT's is standard construction that's been around a long time.  The sticky stuff we call snot.  It's a silicone compound.

Oh I know it is. It's just when you see it close up and think of the relative thicknesses of the bond wire and the surface metallisation at these current levels, and ponder why it doesn't just tear it. It's only sputtered on after all.

Edit: Not to mention the relatively small contact patch.
« Last Edit: February 28, 2020, 10:10:01 am by Gyro »
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Online NiHaoMike

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Re: Renault Zoe EV Power Electronics Block teardown
« Reply #5 on: February 28, 2020, 01:53:46 pm »
The cohesive gel potting compound is commonly used in all sorts of power semiconductors.
http://techno-fandom.org/~hobbit/cars/ginv/i2compon.html
How they get it in without disturbing the thin (control) bond wires I'm not sure, but I would have to guess maybe it's very runny (like honey?) before curing.
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Offline mikeselectricstuff

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Re: Renault Zoe EV Power Electronics Block teardown
« Reply #6 on: March 13, 2020, 08:25:48 pm »
Battery Charger Block ( BCB) :
https://youtu.be/argrHjADn8g
Youtube channel:Taking wierd stuff apart. Very apart.
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