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SKAI® 2 HV – Ultra Compact Converter for Electrified Utility Vehicles

 

SKAI 2 HV comprises a versatile 3-phase AC/DC and DC/AC converter product platform designed for use in electrified vehicles. It covers key requirements such as high power density, exceptional ruggedness and automotive EMI compliance. The integrated motor control software SKAIware ensures highly efficient operation of the electric drive train.

SKAI® 2 HV Benefits

The SKAI 2 HV power electronic platform – now in its 2nd generation – comprises highly integrated converters which provide the ideal powertrain solution for electric and hybrid electric vehicle applications. Power densities of up to 25kVA / litre bring about a notable size reduction compared with other available standard converter products. The products are designed to operate with supply voltages of 120V up to 800V (optional 850V) and with output power ratings of up to 300kVA. Thanks to the elaborate power interface design, all the SKAI 2 HV connections are on the narrow converter front side, reducing assembly space requirements as well as the installation requirements within the vehicle.

The IGBT-based SKAI 2 HV converter operates on sintered 100% solder-free 600V or 1200V power semiconductors and features polypropylene film DC-link capacitors. The DSP-based controller includes gate driver electronics, as well as current, voltage and temperature sensors, and is integrated in a waterproof IP67 enclosure. The compact inverters withstand high vibration amplitudes of up to 10g rms. The embedded SKAIware motor control software adds functionality to the system and completes this tried-and-tested package.

Coupled with the motor control software SKAIware, the SKAI 2 HV monitors the individual power semiconductor junction temperatures in real-time. In this way, the fatigue parameter “junction temperature increase” can be influenced as needed and challenging operating conditions managed. Depending on the software parameterisation it is possible to limit the junction temperature by derating instantaneous power losses in real time. In principle this can be achieved by reducing the actual output current or the switching frequency. The vehicle might slightly derate its actual performance as a result but it will not stop operating. By incorporating the intelligent control feature, the drivetrain performance is more rugged and the expected service life can be guaranteed.

SKAI® 2 HV Key Features

  • Optimised control of permanent magnet synchronous,
  • AC induction and brushless DC motors or generators
  • Torque and speed control mode
  • Field weakening control and derating function
  • Gate drive interface (optional)
  • IP67 enclosure
  • High power density
  • High power cycling and temperature cycling capability thanks to sintered power semiconductors
  • EMI compliant in accordance with UNECE R10
  • Additional engineering services on request

SKAI® 2 HV Applications

The SKAI 2 HV ”Off-the-Shelf“ converter family has been introduced to cover a broad range of vehicle electrification applications. Examples are electric drivetrains with standardised motor/ generator flanges for easy integration into existing vehicle designs. These types of drivetrains have been developed for many vehicle types , i.e. buses, lightweight trucks, agriculture and construction machinery as well as marine applications or cars.

Configurable Converter Platform for E-Mobility

Versatile „off the shelf“
versions

Versatile „off the shelf“ versions

With integrated controller (CAN interface)

  • Full converter with generic drive control software SKAIware
  • Full converter ready to run with customer specific drive software

With integrated gate driver (switching signal interface)

  • Converter with gate driver, protection functions, current, DC-voltage, temperature sensing

Optional services available:

  • End-of-line flashing of customer specific software
  • Individual parameterisation of motor control software

Versatile interfaces
for signal and power

Versatile interfaces for signal and power

For motor position sensors

  • Resolver
  • Sin/Cos encoder
  • Optionally incremental encoder

For motor temperature sensors

  • KTYx/YBBxxx/PTxx/NTCxx

Multi-purpose I/O lines

  • 2 x digital in/out, 2 x analog in

Flexible power connections

  • Cable glands 35mm2-70mm2 optional power connectors for process-safe assembly
  • Optional two DC lines for power distribution

All connections at narrow inverter front end

Fast drive
commissioning

Fast drive commissioning

PC based configuration tool features

  • ECU/VCU simulation
  • Operating values displayed in real-time
  • Variable visualisation and recording with the integrated scope function
  • Configuration via parameter sets
  • CAN logger for supervising and data logging
  • Automated position sensor offset calibration

Additional engineering services on request

SKAI® 2 HV product portfolio

600V IGBT1200V IGBT
SKAI 90 A2 GD06-xQ | with motor control software SKAIwareSKAI 45 A2 GD12-xQ | with motor control software SKAIware
SKAI 90 A2 GD06-xC | with controllerSKAI 45 A2 GD12-xC | with controller
SKAI 45 A2 GD12-xD | with gate driver