Coreless Current Sensing Technology Incorporated into Compact Power Module
Advancements in Electric Vehicle Inverter Design: Integrating High-Resolution, Coreless Current Sensors
In the world of electric vehicle (EV) technology, progress is being made in integrating high-resolution, coreless current sensors into power modules for inverter design. This development is set to revolutionize the efficiency and performance of EV inverters.
Leading the charge is Infineon, with their XENSIV™ TLE4971 and TLE4972 sensors. These sensors, featuring a coreless design, minimize insertion loss and inductance by integrating the primary conductor directly into the sensor package. This innovation enables faster switching semiconductor operation and improved efficiency in inverter modules.
The sensors are fully calibrated, reprogrammable, and come in small leadless packages suitable for standard surface-mount assembly. This compact design is crucial for space-constrained EV inverter modules.
Infineon's 2nd-generation hybrid power module platform (HybridPACK™) takes this integration a step further, vertically incorporating such coreless current sensors into the busbars for optimal space and cost efficiency. This setup supports SiC-based power electronics for EV traction inverters, promising improved range and thermal performance over silicon solutions.
In addition, these sensors support comprehensive system solutions with integrated gate drivers and 32-bit microcontrollers featuring AI-enabled predictive maintenance. This enhancement increases reliability and reduces time-to-market for EV inverter designs.
Meanwhile, LEM has innovated a Hybrid Supervising Unit (HSU) that combines shunt and open-loop Hall effect technologies in a single unit for EV battery management. This approach indicates broader trends in current sensing towards multi-technology and multifunctional units aiming for ASIL-D safety levels in automotive.
Overall, these developments point towards the integration of digitally programmable, compact, coreless Hall effect current sensors with integrated isolation, calibrated factory settings, and diagnostic capabilities directly into power modules and busbars. This integration advances power density, efficiency, and safety in EV inverter designs, aligning with the continued rise of wide-bandgap semiconductors and system-level AI-enhanced control architectures.
These advancements reflect the most recent product releases and system design approaches from leading companies Infineon and LEM as of July 2025. The integration of these sensors is set to streamline inverter design for electric vehicles, promising robust power distribution and improved thermal performance of EV traction inverters.
Data-and-cloud-computing technology can be a valuable tool for optimizing the design and performance of electric vehicle inverters, as it allows for data analysis and remote monitoring of inverter systems. This can help in early detection of potential issues, ensuring increased reliability and reducing downtime.
Advancements in data-and-cloud-computing technology, coupled with the integration of high-resolution, coreless current sensors, present a promising future for electric vehicle inverters, as they enable real-time monitoring, predictive maintenance, and enhanced system-level control architectures.
