Issue link: https://resources.mouser.com/i/1538715
C h a p t e r 3 ARCHITECTING THE ELECTRIFIED POWERTRAIN The electrified powertrain has become the focal point of vehicle design, especially as OEMs shift from mild hybrid platforms toward full-battery electric architectures. Instrumental to this evolution is the transition from 400V to 800V systems, which unlocks faster charging, improved power density, and higher drivetrain efficiency but also introduces new challenges for passive components operating at high voltages and high currents in compact environments. At 800V, components are subjected to twice the voltage stress found in traditional 400V systems. For starters, higher voltages necessitate capacitors with higher dielectric strength and magnetics with tighter creepage and clearance tolerances, all while maintaining minimal size. Thermal performance also becomes a pain point. In fast-charging applications, for instance, components experience rapid and repeated thermal cycling, often going from ambient to full load within seconds. Capacitors and inductors in these systems must survive extreme temperature ramps without degrading, swelling, or losing function. Elevated voltages also introduce complexity into EMI filtering. For example, 400V DC systems may allow 22nF Y-capacitors per rail, while 800V DC systems are limited to 10nF due to increased charge to ground. The ongoing integration of EV powertrain subsystems increases the criticality of each subsystem for overall vehicle safety and reliability. For example, enhanced diagnostics and lifetime monitoring may require passive components with predictable aging characteristics." Pirooz Javanbakht Electrical Engineer, Mercedes-Benz AG 17 Powering the New Automotive Era with Smart Passive Solutions