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WINZ develops a control board that makes it easy to equip hybrid cars with capacitors
"Even our trial car has seen a fuel efficiency improvement of about 15%," the company said.
The digital control substrate developed by WINZ Corporation, a Japanese firm specializing in power control devices, represents a breakthrough in hybrid electric vehicle (HEV) technology. This new control board allows lithium-ion capacitors to be effectively used in HEV energy storage systems. The key innovation is its ability to instantly switch between charging and discharging, even when dealing with large voltage fluctuations.
WINZ has already created a prototype HEV and is conducting tests on the new control board (see Figure 1). The test vehicle features a 3kW induction motor-generator integrated into the generator section of a commercial vehicle. It can be driven or regenerated using a belt-assisted engine. A lithium-ion capacitor is installed in the trunk and uses Asahi Kasei FDK ENERGY DEVICE’s "ECM-45" module. This module is the same size as a traditional lead-acid battery, operates at 45V, and has a capacity of 166F (30Wh).
The control system consists of a bidirectional AC-DC inverter, a bidirectional DC-DC converter, and a digitally controlled microcontroller that manages these components. When fully charged, the trial car can generate 3kW of output power within approximately 36 seconds. According to WINZ, due to the current limitations in motor-generator design, the fuel efficiency has improved by around 15% compared to the original version. However, with proper optimization, this could potentially reach up to 30%.
**Traditional control methods struggle with fast switching**
Currently, lithium-ion rechargeable batteries dominate HEVs due to their high energy density. However, they have high internal resistance, requiring multiple units to achieve high voltage. Additionally, due to lifespan constraints, the actual capacity needed for charging and discharging must be more than double the required amount.
WINZ's prototype hybrid vehicle (a) incorporates motor generators, digital control boards, and lithium-ion capacitors (b) that assist in propulsion.
Lithium-ion capacitors offer superior power characteristics and longer life, making them a promising alternative to lithium-ion batteries in HEVs. They are particularly cost-effective for applications requiring high efficiency, such as commercial vehicles and small-to-medium trucks that operate in urban areas with frequent acceleration and braking.
However, mass-produced HEVs using capacitors like electric double-layer capacitors are still not widely available. While Mazda has implemented regenerative systems using such capacitors in passenger cars, the recovered energy is typically used for vehicle electronics rather than propulsion.
WINZ explains that the main challenge lies in the difficulty of performing fast charge-discharge switching when the voltage changes significantly during operation. For instance, using a bidirectional DC-DC converter with traditional feedback control can result in large currents during switching, which slows down the process and may cause mechanical shocks in the vehicle.
The chopper method based on traditional feedback control requires time for switching, which can lead to knocking sounds in the hybrid vehicle, making it unsuitable for driving assistance.
To address this issue, WINZ has developed a new control algorithm based on digital control instead of conventional feedback methods. Although specific details remain undisclosed, the company claims that no hardware changes are necessary. By adjusting the duty cycle of two switching elements through digital control, the system can charge and discharge instantaneously at any voltage level.
WINZ achieves instantaneous charge and discharge at any voltage by digitally controlling bidirectional DC-DC converters.
WINZ stated that by simply adjusting the settings of the newly developed control algorithm, the system can be adapted for both passenger cars and trucks. For smaller and medium-sized trucks, installing a motor in the rear axle and equipping it with a lithium-ion capacitor can significantly improve fuel efficiency. Therefore, the company is promoting this solution as an external upgrade option. (Reporter: Hiroshi Koji, Nikkei Electronics)