Maximizing Hybrid and Electric Vehicle Power Efficiency

MPS Industries, Inc. was proud to participate in this year’s Electric & Hybrid Vehicle Technology Expo. Undoubtedly the largest H/EV trade show in North America, the expo brought together over 8,000 automotive engineers and executives and more than 600 leading suppliers from across the industry and around the globe. The event provided a great opportunity for companies to display their latest electric and hybrid products, solutions, and technologies under one roof.

This year, MPS Industries took the opportunity to showcase our line of magnetic components designed specifically for the automotive industry. We presented our products to a wide audience and networked with hundreds of industry professionals who expressed interest in our innovative solutions. Based on this feedback, we wanted to discuss the importance of transformers and inductors in electric and hybrid vehicles.

Transformers and inductors are one of the most critical components in a vehicle’s power transmission system. These simple yet powerful devices are primarily responsible for a vehicle’s power performance and efficiency. Below, we discuss the role that transformers and inductors play in both electric and hybrid cars.

Hybrid Vehicles

Components in hybrid vehicles are regularly subjected to harsh conditions such as extreme temperatures and excessive vibration. Hybrid transformers and inductors must therefore be capable of operating in such environments while efficiently delivering power to the vehicle’s various systems. The most reliable of these electronic components have an operating temperature range between -55oC (-67oF) and +150oC (302oF).

In hybrid vehicles, component installation space is usually restricted; this is especially challenging since the surrounding equipment generates a large amount of heat. Transformers and inductors need to be located in areas with ideal cooling and ventilation access. Because of these limitations, transformers and inductors must meet specific size and weight requirements for use in hybrid vehicles. Once optimally sized and correctly installed, these magnetic components can achieve input to output energy efficiency ratios of up to 99%.

MPS Industries offers a variety of high current fixed inductors designed to withstand the extreme physical environment and power load demands of the typical hybrid vehicle. Their exceptional heat dissipation properties and minimal power loss at high frequencies ensure that they can operate at high temperatures with minimal effect on performance. Additionally, our inductors are designed to be compact, reducing the likelihood of issues arising due to spatial constraints.

Electric Vehicles

Electric vehicles typically have greater power demands than hybrid or gasoline powered vehicles. Complex drivetrain management, traction motors, and other necessary features are high consumers of electrical energy; electrical load requirements are further compounded by the addition of convenience features such as auxiliary heating and cooling systems. As such, electric vehicles require transformers and inductors that can meet the needs of these increasing demands.

Magnetic components in electric vehicles must not only be able to withstand considerable amounts of heat and voltage, but they must also help in maximizing fuel efficiency and minimizing CO2 emissions. Furthermore, similarly to hybrid vehicles, transformers and inductors in electric cars must also be able to handle excessive amounts of vibration.

MPS Industries’ Switching Transformers are an ideal solution for all types of electric vehicles. These transformers help manage temperatures for considerably improved fuel efficiency. We offer Phase Shift Full Bridge Transformers and Inductors that feature Zero Voltage Switching (ZVS), which allows for high-frequency and high-voltage operations without compromising system efficiency.

Transformers & Inductors from MPS Industries

MPS Industries, Inc. is a leading provider of electronic components for a broad spectrum of industries and applications. With manufacturing processes certified to TS16949 and strict adherence to PPAP and IMDS requirements, we specialize in the manufacture of transformers, inductors, and other electromagnetic components for the exacting specifications of the automotive industry.

Our ISO 9001:2015 and ISO 14001:2015 certifications are a testament to our commitment to producing high-quality magnetic components while aligning with environmental sustainability goals.

At MPS Industries, Inc., our engineers and technicians collaborate closely with automotive clients to design and manufacture custom high-performance solutions tailored to meet or exceed their mechanical and electrical specifications.

If you have questions about MPS’ transformer or inductor options for hybrid or electric vehicles, or if you would like to learn more about our work within the automotive industry, contact us today!

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