Suncall Corporation Taps Crocus Technologies TMR Sensor Technology to Develop Advanced Sensors for EV Industry
Suncall Corporation, Ltd., an auto parts manufacturer based in Kyoto, Japan, has launched a new lineup of electric vehicle products based on a magnetic sensor built around an integrated sensor from Crocus Technology. This new current sensor achieves high accuracy of 1.0% or less over the entire temperature range and low power consumption of 6mA or less, making it more efficient than conventional products.
The demand for EVs is growing rapidly worldwide, and it’s predicted that by 2025, more than half of all new car sales will be electric. Suncall Corporation’s current sensor is essential for high-precision sensing in electric vehicles, especially for a long-life drive battery and a precise control system for charging and discharging.
Suncall’s new magnetic current sensor measures current by reading the magnetic field generated in power distribution systems using integrated TMR magnetic sensors. It was developed in collaboration with Crocus Technology, ensuring highly accurate and versatile sensing solutions that differ from conventional products. Suncall’s development team focused on ensuring accuracy and highly efficient sensing technology to extend the driving distance and battery life.
The magnetic current sensor developed by Crocus and Suncall is integrated with the busbar, eliminating the need for position adjustment between the sensor and the busbar. With the power consumption required for operation reduced to 6mA, the sensor can operate with about one-fifth of the energy of the traditional shunt-only solution, reducing the environmental burden. Suncall plans to expand sales of current sensors in Europe and the United States, aiming for current sensor business sales of 1 billion yen in 2024 and 2.5 billion yen in 2025.
During the development of the magnetic current sensor, Suncall’s team understood the importance of accuracy. As electric vehicles depend on the constant measurement of current flow to manage the charging and discharging of their lithium-ion batteries, highly accurate current sensing technology is essential to extend the driving distance and battery life.
Suncall selected magnetic sensor integrated circuits from Crocus to achieve this accuracy. Suncall selected Crocus Technology’s Tunnel Magneto Resistance (TMR) sensor because it has the highest level of precision among magnetic sensors and is a rare technology that only a few companies in the world can supply. US car manufacturers and others have already adopted this chip, proving its quality and effectiveness, and Crocus was able to meet their stringent delivery times of 12 weeks.
In collaboration with Crocus, Suncall devised a method to implement TMR for current detection applications in devices with high currents, such as inverters for controlling high-power motors for automobiles. This method involved implementing busbar mounting for large current applications of TMR sensor ICs, making it the first attempt in the industry. Through this innovative approach, Suncall has made significant strides in improving the accuracy of its magnetic current sensor, which will ultimately benefit the EV industry as a whole.
This new magnetic current sensor is essential for the future of the automobile industry, as it offers a more efficient and accurate way to detect current in EVs. With the shift to EVs continuing to accelerate globally, Suncall’s product launch comes at a crucial time, meeting the high demand for long-life drive batteries and precise control systems for charging and discharging.
Suncall’s collaboration with Crocus is a significant milestone in the development of the magnetic current sensor. By implementing TMR for current detection applications in devices with high currents, Suncall is breaking new ground in the industry, paving the way for further innovation and growth.
Moreover, Suncall is also developing a sensor with two different measurement ranges, low current and high current, and a dual method that combines a shunt type and a magnetic type. This development is in response to the functional safety requirements of ISO26262, which place importance on ensuring redundancy to maintain the functions of the entire system even after a failure occurs in some part of the system.
The new product was unveiled at the Automotive World EV/EHV/FCV Technology Exhibition in January 2023 and has already received a great response. With plans to open offices in Europe and the United States, Suncall is well-positioned to expand its sales of current sensors globally.
Suncall’s launch of the magnetic current sensor is a significant milestone in the automobile industry’s shift towards EVs. By providing highly accurate and efficient sensing technology, Suncall is helping to extend the driving distance and battery life, contributing to the electrification of the world.
Suncall’s new magnetic current sensor is essential for the automobile industry and other industries, such as automatic transporters, EV charging stations, and solar power generation systems. The sensor’s high-precision sensing capabilities can be utilized in various applications, making it a versatile product that can contribute to the growth of other industries.
Suncall’s collaboration with Crocus is also significant as it highlights the importance of global partnerships and cooperation in the technology industry. By leveraging each other’s strengths, Suncall and Crocus were able to develop a new product that offers a unique solution to the current shortage of electronic components.
As the demand for EVs continues to grow globally, Suncall’s current sensor business sales are expected to reach 1 billion yen in 2024 and 2.5 billion yen in 2025. This growth will benefit Suncall and contribute to the growth of the EV industry and the transition toward a more sustainable future.
Suncall’s launch of the magnetic current sensor is a significant step towards a more efficient and sustainable future. By providing highly accurate and efficient sensing technology, Suncall is contributing to the electrification of the world and creating new opportunities for growth in various industries.
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