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Military Move to Electric Vehicles Creates New Challenges for EMI Filter Manufacturers





The World’s Military Forces are recognizing the benefits of having vehicles capable of operating from electric sources of power. The impetus for the move to electric vehicles is both strategic and economic. Stealth is enhanced by the near-zero thermal signature of both the electric vehicle and electric weapons launching systems. The savings are substantial in both vehicle efficiency and the cost of fuel transport to the theatre.

There are numerous challenges to fielding the hybrid and all-electric combat vehicle (AECV) not the least of which is size and weight of batteries and direct-drive electric motors. High-ampacity electric vehicle propulsion systems are capable of delivering over 100 horsepower to each individual wheel. Combustion engines are being replaced by generators responsible for recharging batteries used for motive power. There are significant electromagnetic interference (EMI) issues in charging and operation which require mitigation through the use of AC and DC power line filters. The challenge to EMI Filter manufacturers is to provide high performance in as light a filter as possible.

The drivetrain is not the only issue with respect to EMI on today’s fighting vehicles. The content of electronic systems on these vehicles is immense. These systems also require light-weight, high-performance EMI Filters to comply with the Military EMI Standards such as MIL-STD461E/F. Materials and methods must be employed to simultaneously address high-ampacity, high insertion loss, and ruggedness in a compact, light-weight design.

With small size and low weight being the primary design goals, filter manufacturers must turn to high-quality, high-permeability inductors and light-weight feed-through capacitors integrated into as small an enclosure as is possible. Choice of high grade compound potting materials also play a key role in thermal dissipation and as a firmament to internal components assuring excellent shock and vibration response as required in these types of applications. The potting compound selected also plays a key role in the resultant ambient temperature rating of the filter (it is not uncommon to have ambient requirements in excess of 70C). Care needs to be taken in selecting a potting compound which has all of these attributes but does not impart any excessive stresses on the inductor cores upon curing. The induced stresses caused by inferior potting compounds can diminish the performance of inductors well below their anticipated levels.

The EMI performance range required of a military rfi filter is typically defined by testing specification MIL-STD461E/F. The filter must be capable of attenuation from 10Khz to 30Mhz as a minimum. In some cases multi-GHz performance is required to mitigate noise issues which may be encountered in high bandwidth transmission protocols associated with modern communications equipment. This broad range frequency attenuation is achieved by integrating progressive stages of filtering within the same (metal) filter housing.
Each stage is completely insulated from the next by the use of hermetically sealed bulkheads and insulated bushings on the internal terminations.

With the proliferation of electrical systems on the battlefield, the need for robust EMI Filtering in a compact and lightweight format is critical. Every ounce saved in components such as these is another ounce added to payload. In selecting an EMI Filters for your Military application, consider the cost and time-to-market advantages of a commercial-off-the-shelf vendor with a broad range of AC and DC solutions.

About Radius Power, Inc.

Radius Power introduced the RPM Series of AC and DC Power Line Filters designed specifically to address three ranges of Military type applications; MIL-STD461E/F (standard and extended performance) and DO-160 for Avionics/Aerospace requirements. There are currently four families of DC Filters (RPM6000) and four families of AC Filters (RPM7000) with ampacity ratings spanning from 5A to 60A. For 3-Phase DELTA & WYE applications, Radius Power offers the RPM8000 and RPM8500 Series respectively. These products are available with ratings from 5A to 150A. The RPM9000 Series is a novel, dual-stage filtered IEC for use in ruggedized applications from 5A to 20A.

All of the RPM Series Products are manufactured by Radius Power in our ISO9001:2008 certified manufacturing plant in Southern California. These products are commercial-off-the-shelf (COTS) and as such carry no international export restrictions (ITAR).
About Author George Wells :

George Wells writes on behalf of Radius Power the Global manufacturers of Standard and Custom <a href="http://www.radiuspower.com" target="_blank">emi rfi filters</a>. To learn more about <a href="http://www.radiuspower.com/military-emi-filters.html" target="_blank">military rfi filter</a>, visit <a href="http://www.radiuspower.com/military-emi-filters.html" target="_blank">www.radiuspower.com/military-emi-filters.html</a>


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Article Added on Wednesday, December 12, 2012
LD
Other Articles by George Wells

On Moore s Law and Electromagnetic Interference
State-of-the-art transistor technologies bring unparalleled power density and efficiency to a myriad of power conversion applications. The relentless charge down the semiconductor process technology roadmap guarantees ever faster switching speed (dV/dT) and an unintended consequence, electromagnetic interference (EMI). Moore’s Law has been around a long time. Simply stated it predicts that the number of available gates on a fixed silicon area will double every 18 months based on the...

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