Hall sensor in inverter design reduces cost

Silicon Austria Labs (SAL) has collaborated with Asahi Kasei Microdevices (AKM) to create a groundbreaking proof of concept by integrating a Hall current sensor into a power module designed for automotive traction inverter and DC-DC converter applications. This innovative module, developed with next-generation silicon carbide (SiC) power devices, not only enhances energy efficiency but also reduces the size and weight of high voltage inverters, marking a significant advancement in electric drive systems.

Traction inverters are vital components in xEVs, responsible for powering the electric drive motors by converting direct current from the battery into alternating current. The seamless operation of these inverters across various driving conditions necessitates precise current sensing over a wide dynamic range. The power module design incorporates the EZ232L linear Hall IC for coreless current sensors from AKM, offering a solution that surpasses the limitations of traditional magnetic core-based sensing methods.

The utilization of the EZ232L Hall IC enables the power module to leverage standard printed circuit boards with direct copper bonding of the SiC MOSFETs, eliminating the need for costly ceramic substrates. This design choice not only reduces manufacturing expenses but also enhances the overall efficiency of the module. The integration of gate driving circuits and current sensing capabilities further enhances the flexibility and cost-effectiveness of the module for small-to-medium production volumes.

At the forefront of this technological breakthrough, Thomas Langbauer, Team Lead within the Power Electronics Division at SAL, emphasized the significance of the designed power module in setting a new standard for current sensing in power modules. The collaboration between AKM and SAL has yielded an innovative solution that is poised to revolutionize the landscape of xEVs traction inverters, making them smaller and lighter while maintaining optimal performance.

Looking ahead, AKM is set to showcase the results of the inverter module developed in partnership with SAL at PCIM Europe 2025 in Nuremberg, Germany. This event will serve as a platform to demonstrate the latest advancements in power technologies, underscoring the commitment of both companies to driving innovation in the automotive sector and beyond. The joint effort between AKM and SAL signifies a significant milestone in the evolution of current sensing technology within power modules, paving the way for more efficient and sustainable electric drive systems.