Ingeteam and ModCap

Ingeteam, a global leader in electrical energy conversion, has partnered with TDK to optimize its renewable energy solutions. By integrating TDK’s ModCap capacitors, Ingeteam achieves superior high-frequency performance and reliability, even under extreme conditions. This collaboration not only accelerates Ingeteam’s time to market but also simplifies its product portfolio and boosts competitiveness. Additionally, the use of sustainable materials in ModCap capacitors aligns with Ingeteam’s commitment to environmentally friendly solutions. This partnership exemplifies the power of innovation and technical expertise in driving forward the renewable energy sector.

Meet Ingeteam: Pioneers in Sustainable Energy Solutions

Ingeteam is a global company with about 3,500 employees in 15 countries. Founded in the year 1972, it has many years of experience in providing innovative solutions to specific problems, to electrify society innovatively and sustainably through state-of-the-art technology specializing in the conversion of electrical energy. Ingeteam generated a turnover of 842 million euros in 2022. Around 40 million euros were invested in R&D. Ingeteam’s focus is on renewable energy generation (wind, solar, hydro), energy storage, smart grid solutions, and efficient energy use. The products of the company include chargers for electric vehicles, converters, alternators, and engines for various sectors such as marine, steel, mining, and water management.

Overcoming Extreme Conditions: Ingeteam’s Quest for High-Performance Capacitors

Focusing on innovation and performance in the renewable energy market requires components that can withstand extreme operational conditions. This includes elevated temperatures due to direct sunlight and confined spaces, high humidity, and salt spray from seawater. In addition, Ingeteam has been working with a new generation of semiconductors. Wide bandgap power semiconductors like silicon carbide (SiC) MOSFETs push the limits of performance and efficiency by switching much faster than silicon IGBTs. This fast switching poses extra stress on the surrounding components like the DC-link capacitor.

The key challenge lies in finding capacitors that can perform under the high-frequency demands of these converters while maintaining high current capability, low ESR (Equivalent Series Resistance), and low ESL (Equivalent Series Inductance), all within a compact size. A low ESR is important because it minimizes energy losses and improves performance in high-frequency high-power applications. Similarly, low ESL is crucial as it enables faster transient response and lower EMI. Specifically, when using fast-switching devices like SiC MOSFETs and the latest silicon IGBTs, the ESL must be extremely low to reduce voltage overshoots at turn-off. A low ESR also limits self-heating, thereby improving the thermal performance of the component. Together, low ESR and ESL enhance the overall stability and reliability of the converter.

With all these challenging demands, Ingeteam needed a solution that not only met their stringent technical specifications but also allowed standardization and modularization across their range of products.

Introducing ModCap: TDK’s High-Frequency Solution for Ingeteam’s Challenges

In response to these challenges, TDK offers its ModCap HF capacitors – a solution designed specifically for high-frequency applications with superior power density and performance.

They offer several advantages that directly address Ingeteam’s requirements:

• Compact: Due to its flat winding design and internal configuration, ModCap is one of the most compact modular DC-link capacitor solutions currently available on the market. This allows our customers to use smaller busbars and offers a lighter, more compact product.
• High-Frequency Performance: ModCap HF capacitors are optimized for high-frequency operations, making them a good fit for the new generation of converters that use SiC-based or latest-generation IGBT power semiconductors.
• High Current Capability: The capacitors are designed to handle high currents, ensuring high-power energy conversion in demanding conditions.
• Ultra-low ESR and ESL: These capacitors feature ultra-low ESR and ESL, which are crucial for good thermal and electrical performance in converter systems.
• Cost Efficiency: By shifting from traditional customized MKK capacitors to standard PEC HP capacitors, Ingeteam benefits from significant cost savings, making their solutions more competitive in the market.
   

“Supporting Ingeteam with ModCap has been an incredible experience. Utilizing advanced simulations like FEA, we've optimized capacitor performance to meet their specific needs. This partnership truly highlights the power of teamwork and technical expertise.” 

Natalia Iriondo, Product Marketing Manager

Strengthening Bonds: Ingeteam and TDK’s 15-Year Collaboration

Ingeteam has been a valued customer of TDK for over 15 years, with a history of collaboration on various capacitor technologies. Thanks to this long-standing relationship, Ingeteam was one of the first companies to collaborate with TDK on the design of new converter systems using ModCap capacitors. This collaboration began with traditional solar inverters, then expanded to energy storage systems (ESS) and later INGECON H2 E series rectifiers for hydrogen generation, along with traction inverters for electric vehicles.

Ingeteam greatly values TDK's technical expertise and the support it provides through advanced simulations (such as FEA—Finite Element Analysis) to ensure the optimal performance of the capacitors in their applications. The close technical partnership between the two companies has been crucial in addressing the specific needs of Ingeteam’s products.

“TDK's technical expertise and the advanced simulations they provide, such as Finite Element Analysis, were key to optimizing our applications. Their support and the close technical partnership we share have been crucial in meeting our product requirements and reducing time to market.” 

Roberto Gonzalez, Global Technical Director - Solar, Ingeteam

Impressive Outcomes: How ModCap Capacitors Transformed Ingeteam’s Performance

The integration of ModCap capacitors has delivered impressive results for Ingeteam. Key outcomes include:

• Reduced Time to Market: The use of standardized ModCap capacitors has significantly reduced the time required for technical validation of Ingeteam’s converter systems. This allows Ingeteam to bring new products to market faster, a critical advantage in the highly competitive renewable energy sector.
• Simplified Product Portfolio: By moving to a standardized solution, Ingeteam has simplified the bill of materials for their converter portfolio, streamlining the design process and reducing complexity.
• Increased Competitiveness: With the cost-effective, high-performance ModCap capacitors, Ingeteam has been able to deliver highly competitive converter systems that meet the growing demands of the renewable energy market.
• Sustainability: Ingeteam appreciates TDK’s commitment to sustainability, particularly using biocircular polypropylene film in ModCap capacitors, which aligns with their own focus on environmentally friendly solutions. The use of ISCC-certified Bio PP film is unique to ModCap, providing a sustainable edge in the market.

Conclusion: A Successful Partnership Driving Innovation and Sustainability

Ingeteam’s partnership with TDK has proven to be a successful collaboration, enabling the company to meet the stringent requirements of state-of-the-art converter systems. By adopting ModCap capacitors, Ingeteam has been able to overcome challenges related to high-frequency performance, cost, and time-to-market, while also advancing their sustainability efforts. The use of standardized high-performance capacitors has helped Ingeteam remain competitive in the rapidly evolving renewable energy market. The continued collaboration with TDK positions Ingeteam for future success, as the company continues to innovate and lead the way in sustainable energy solutions.

With ModCap capacitors, Ingeteam has not only addressed the technical challenges of next-generation converters but also paved the way for more efficient, cost-effective, and sustainable energy solutions. This successful collaboration exemplifies how the right components, supported by strong technical partnerships, can drive innovation and success in a fast-paced industry.

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