Panasonic's passive components form the foundation of many modern mobility solutions: supporting the operation of electric vehicles, high-speed train systems, the performance of electric bicycles, and the reliability of agricultural machinery.
Current progress largely depends on the development of transportation, highlighting the critical importance of advanced transportation systems. Today's transportation infrastructure encompasses a wide spectrum of machines: from passenger vehicles and commercial vehicles to railway networks, electric bicycles, and Automated Guided Vehicles (AGV) used in industrial and agricultural applications. To properly understand the advancement of these systems, we must focus on the basics of electronics, specifically on passive components. The evolution and reliability of modern transport largely depend on significant achievements in this fundamental field.
Utilizing the state-of-the-art LCR technology from Panasonic — known for high performance, exceptional efficiency, safety, and reliability — our transportation networks have become safer, smarter, and more efficient than ever before.
Changing Market Requirements in the Transportation Sector
The acceleration of electrification and automation has radically changed the requirements for components across the transportation industry. They must be highly reliable and handle high currents.
Consider also the rapid growth of the electric bicycle market:
increased motor power: from 500W to over 750W;
increase in system voltage from 36V to 48V, and even 60V;
integrated design: compact modules with high functionality.
To meet these changing requirements, key features of components include:
high current performance (low DCR and ESR for increased efficiency);
thermal stability (guaranteed operation over a wide temperature range, e.g., from -55°C to 170°C);
miniaturization (space-saving components for surface mount, SMD);
reduction of electromagnetic interference (reduced level of emitted noise);
long life and high performance throughout the service life.
Hybrid Capacitors – Performance and Durability
Leading Panasonic hybrid capacitors with ultra-low ESR and high capacitance enable the realization of compact designs without sacrificing performance, facilitating the creation of integrated infotainment and control systems in vehicles. From ensuring smooth, reliable operation in electric and autonomous vehicles, through supporting the high-speed requirements of railway systems, to powering electric bicycle drives and agricultural machinery — Panasonic passive components form the basis of modern mobile solutions.
Technical Challenges in Transportation Applications
Handling high currents. Electric bicycles and AGV vehicles with output power from 500W to 6kW require DC-link capacitors capable of carrying ripple currents of 20…60A. Conventional electrolytic components require the use of multiple elements, increasing the printed circuit board area.
Long-term reliability. Electric vehicles and AGV vehicles now require a 10-year lifespan with over 4000 hours of operation at 125°C, exceeding the typical warranty of 2000 hours for traditional electrolytic capacitors.
Safety in emergency modes. Although polymer capacitors withstand high currents, in the event of a failure there is a risk of short-circuiting, which can lead to a fire or system shutdown. Automotive and industrial standards require open-circuit emergency modes to prevent secondary damage.
Panasonic Hybrid Capacitor Technology
Panasonic hybrid capacitors combine electrolytic and polymer technologies to comprehensively address the issues described above.
Performance comparison (e.g., 47µF, 35V):
• combining high reliability of electrolytic capacitors (low LC, open mode) with high current performance of polymer capacitors (low ESR);
• twice the durability compared to conventional capacitors
• 4.5-fold increase in allowable ripple current.
Hybrid cap has High Reliability (Low LC, Open mode) and suitable for Large Current (Low ESR)
35V47uF (Dia 6.3mm)
E-Cap
Hybrid
Polymer Cap
Electrolyte
Liquid
Polymer + Liquid
Polymer
LC (mA)
◯ 0.01CV
◯ 0.01CV
✕ 0.2CV
Life end mode
◯ Open
◯ Open
✕ Open (Accidental short)
Humidity
◯ 85℃ 85%RH
◯ 85℃ 85%RH
✕ 60℃ 95%RH
Endurance
✕ 125℃ 2000h
◯ 125℃ 4000h
✕ 125℃ 2000h
Ripple current (125℃ 100kHz)
✕ 197 mA
◯ 900 mA
◯ 1000 mA (* 3100mA at 105℃)
ESR (20℃ 100kHz)
✕ 450 mΩ
◯ 60 mΩ
◯ 26 mΩ
Low temperature, High-frequency characteristics
✕ Unstable
◯ Stable
◯ Stable
legend:◯ : good ✕ : bad
Key Product Series
The most important Panasonic product series in the hybrid component offering:
ZUU – very high capacity and handling significant ripple current.
In the table below, the distinguishing features of each series are presented:
Series
Capacity
Ripple Current
Miniaturization
ZTU
1.7 times greater than the basic hybrid series (e.g., 330µF → 560µF, φ10×10.2mm)
1.8 times (e.g., 2900mA → 3500mA)
φ10×10.2mm → φ8×10.2mm (smaller casing with the same capacity)
ZUU
Series with the highest capacity up to 1000µF
Largest series ripple current up to 6100mA
Cost and space savings thanks to 1-to-many replacements.
Example Application in Electric Bicycles
Below are two proposals for using Panasonic hybrid capacitors in electric bicycle circuits. The initial assumption is a 6kW drive inverter design for a three-phase motor. The circuit is powered by a 48V lithium-ion battery.
Conventional design would involve using 12 capacitors of 150µF (63V) with dimensions φ10×16.5mm.
Proposal 1 (ZUU): 63V, 180µF, φ10×16.5mm × 8 pcs.
• total capacity: 1440 µF
• ripple current: 44A RMS
• number of components reduced by 33%
Low-profile design (height reduced from 16.5mm to 12.5mm, a reduction of 24%). Increased circuit performance using the proposed components.
Example Application in Automotive
As mentioned, a significant area where the use of Panasonic components helps, among other things, to reduce circuit dimensions is automotive. Let's see what such miniaturization looks like in practice.
Example: Electric Power Steering (12V, 500W)
Conventional design would require the use of 4 capacitors at 25V with a capacity of 470µF, each measuring φ10×12.5mm. Using Panasonic components (ZUU series) only 2 pieces of 25V, 1000µF are needed, each measuring φ10×16.5mm. This gives parameters:
• capacity: 2000 µF (+6.4%),
• allowable ripple current 12.2A RMS,
• number of components reduced by 50%. Comparison of both circuits considering the required PCB area.Example: Cooling Fan (24V, 4kW, Three-Phase Motor)
In a standard design, 11 capacitors of 470µF/35V would be used, each measuring φ10×16.5 mm. ZUU components reduce this number to 9 pcs. of 680µF/35V components (φ10×16.5mm). This means a change:
• 18-percent increase in total capacity (6120 µF),
• 18-percent decrease in number of components. Hybrid capacitors not only improve parameters but also reduce PCB area.Example: DC-DC OBC Onboard Charger Converter
Typically, a converter of this type will operate at parameters: 400V output voltage at 12V output. Conventionally, 8 pcs. of 470µF/25V capacitors would be used in its circuit, each measuring φ10×10.2mm. Panasonic reduces this number to 5 pcs. of ZV series components with parameters of 330µF/25V ( φ10×10.2 mm). In this way, two goals are achieved:
• number of components reduced by 38%,
• maintaining equivalent performance thanks to the ESR characteristic. Better ESR parameters allow the use of a capacitor arrangement with a smaller capacity.
Compact Power Coil Design
Panasonic power coils combine advanced materials science with state-of-the-art design, providing excellent performance across a wide range of applications. Thanks to Panasonic's patented metal composite (MC) core technology, these coils achieve current conduction up to 103A, while maintaining compact sizes from 5×5mm to 15×15mm. The MC core structure provides low DC resistance, high saturation current, and excellent heat dissipation, enabling stable and efficient power conversion in space-constrained environments. Panasonic power inductors, ideal for use in automotive, industrial, and telecommunications systems, provide designers with a versatile solution for high-performance DC-DC converters, voltage regulators, and next-generation power modules.
Technical Challenges and Solutions
Limiting electromagnetic interference. High-frequency switching in electric bicycles and AGV vehicles generates electromagnetic interference. Conventional inductive coils with ferrites have high magnetic flux leakage, which makes it difficult to meet electromagnetic compatibility (EMC) standards.
Miniaturization limitations. With system voltage increasing to 48…60V, inductive coils must withstand currents above 5A without significantly increasing in size.
Temperature management. Operating at high current intensity causes temperature rise, affecting the stability of inductance and circuit performance, especially near motors. Panasonic inductive coils provide industry-leading reliability and excellent thermal stability.
The parameters of Panasonic's MC Core coils are the answer to all of the challenges mentioned above.
Dimensions
Below is a comparison of compact Panasonic coils (metal composite core) and standard inductive elements (ferrite) 22µH. The table highlights a significant difference in size and saturation current value.
Low Level of Electromagnetic Interference
Flux loss in inductive coils with a metal composite core is significantly lower compared to ferrite-based elements. Reduced stray flux means a lower level of radiated noise, which facilitates meeting EMC requirements for automotive and AGV applications. Comparison of electromagnetic radiation for ferrite and MC elements from Panasonic.
Inductance Stability
Another advantage of Panasonic's MC coils is stable inductance, which manifests in three properties:
• no hard saturation characteristic;
• stable performance across the entire temperature range;
• high tolerance for transient currents. Hard saturation characteristic for ferrite elements and MC core elements.Reliability
It is also worth noting a few features of Panasonic coils (specific to selected models). They relate to the durability of these components. These include:
• compliance with AEC-Q200 standard;
• operating temperature range from -40°C to 150°C;
• resistance to vibrations up to 50G;
• withstand voltage: 80V (provides a 67% margin for 48V systems).
Application in Electric Bicycle/AGV Circuits
The illustrations below show the application of Panasonic MC core coils in typical circuits for smaller electric vehicles. In the diagram, the coil is placed to stabilize the current flowing from the battery pack.Filtering coil in the power supply circuit of a three-phase motor controller.
Working in Battery Systems
It is worth noting a number of advantages associated with the use of Panasonic coils in lithium-ion battery systems (e.g., 48V).
• Space savings due to BMS board design: achieved through miniaturization (reducing area by 57%, reducing volume by 74%).
• Simplified measures to counteract electromagnetic interference: thanks to low stray flux.
• Provided design margin: thanks to high saturation current capacity.
• Increased reliability: maintained thanks to thermal stability.
• Handling higher system voltages: suitable for applications from 48 V–60 V and higher.
• High resistance to high voltage and current: optimized for next-generation power systems.
• Thermal stability of inductive coils: ensures consistent performance at elevated temperatures.
• Integrated compact designs: ideal for low-profile, surface-mounted (SMD) applications.
High-Performance Chip Resistors
Panasonic chip resistors provide essential support in transportation systems where power density, precision, and environmental resistance are critical.
ERJP and ERJB series deliver high power in compact packages, ideal for high-power circuits in electric vehicles and e-bikes. For precise control, the ERA series offers tight tolerance and a low TCR. In harsh environments such as agricultural and railway applications, the ERJU series provides sulfur resistance and long-term reliability, supporting safe and efficient operation across various transportation platforms.
Required Circuit Characteristics in the Transportation Sector
The table below presents typical resistor requirements for transportation applications and indicates which Panasonic products are best suited for each use case.
The table below presents typical resistor requirements for transportation applications and indicates which Panasonic products are best suited for each use case.
Function
Key Requirements
Technical Challenges
Recommended Solutions
Voltage measurement
High precision (±0.1%), low temperature coefficient (TCR) (~25 ppm), long-term stability.
Accurate detection of small voltage changes and temperature drift.
High-precision ERA series resistors.
Voltage divider
High voltage resistance (500V), wide resistance range (10MΩ), compliance with creepage and clearance requirements for high-voltage safety.
Series connection of resistors for high voltage increases component count and PCB area and complicates creepage requirements on compact PCBs.
High-voltage resistors: ERA8P and ERJPM8 series.
Current sensing
Low resistance, high power (1…3W), temperature stability (155°C).
Heat generated by high current combined with vibration and high-temperature stress can lead to measurement errors.
Current sensing resistors: ERJB/D and ERJ*BW series.
Gate control
High power (3W), excellent heat dissipation during continuous operation, thermal stability in harsh automotive environments.
Continuous power dissipation in gate control causes thermal stress and resistance drift, affecting reliability.
High-power resistors ERJP or ERJB/D.
Environmental reliability
Resistance to environmental conditions (sulfur, vibration), long-term reliability.
Sulfur-containing gases, humidity, and exposure to high temperatures in harsh environments.
Sulfur-resistant resistors: ERJU/S series.
Addressing Specific Challenges
The features of the individual series described in the table above have a real and significant impact on electronic circuit design. Below, these aspects are presented using specific examples.
Voltage Measurement and the ERA Series
Accurate detection of small voltage changes requires minimizing resistance drift caused by temperature fluctuations. Transportation systems operate under harsh conditions at temperatures ranging from –40°C to 125°C or higher; therefore, a low TCR and long-term stability are essential to ensure reliable operation. These characteristics are provided by ERA series resistors (thin-film resistors).
Key features:
• resistance tolerance of ±0.1%, TCR: ±25 ppm/K;
• limited degradation of performance and reliability during long-term use and temperature fluctuations;
• improved overall tolerance ensures long-term reliability.
High reliability is achieved through the use of a patented resistive material (±0.1% tolerance after endurance testing). Construction of ERA thin-film resistors and their stable characteristics over time
Voltage Dividers with ERA8P and ERJPM8 Series
In BMS voltage sensing circuits, series-connected battery cells generate high voltages (from 300 V to 500 V). To handle this, many low-voltage resistors are traditionally connected in series, increasing the number of components and required PCB area, creating design and cost challenges. In addition, ensuring sufficient creepage distance between high-voltage nodes on a compact PCB is crucial for safety compliance, further complicating the circuit design. This is where ERA8P and ERJPM8 series resistors provide an effective solution.
Key characteristics include:
• maximum element voltage rating of 500 V;
• resistance tolerance: ±0.1%, TCR: ±15 ppm/K (ERA8P);
• compliance with the AEC-Q200 automotive standard;
• reduction in the number of resistors used. Use of Panasonic resistors to build a voltage divider.
By achieving a highly accurate voltage division ratio (VD = V × R2/(3R1+R2)) in the battery voltage sensing circuit, BMS accuracy is significantly improved. In addition, Panasonic components allow a reduction in the number of resistors used:
It should be noted that the actual reduction in component count depends on insulation distance regulations.
Comparison of circuits built using typical resistors and ERJPM8 series components.
Resistance value x usage
Resistance tolerance (%)
TCR (x10⁻⁶/K)
Working voltage (V)
PCB sizing* (mm²)
Current :
Other company
2012 Thin film resistance
300 kΩ
x 10 in-line
± 0.1
± 25
150 x 10 p
= 1500
40.25
Suggestion A : ERA8PEB
1206
Thin film high resistance
1 MΩ
x 3 in-line
± 25
500 x 3 p
= 1500
21.15 (About 48% Reduction)
Suggestion B : ERJPM8F
1206
High resistance and high withstand voltage
± 1
± 100
21.15 (About 48% Reduction)
Current Sensing: ERJB/D and ERJ*BW Series
High current generates significant heat, which, combined with vibration and thermal stress, can cause resistance drift and measurement inaccuracies. Current sensing circuits—such as those used in EV traction systems, charging systems, and fuse protection—require low-resistance, high-power resistors with excellent stability to ensure reliable operation. For such applications, Panasonic offers ERJB/D and ERJ*BW series components.
The ERJBW series (double-sided resistive element type) features very low resistance values (down to 5 mΩ) and a unique construction that provides high power in a smaller package**, contributing to PCB size reduction. Cross-section showing the double-sided resistive element structure.Size reduction resulting from the use of components in the 0805 package.
The ERJB/D series (wide terminal type) reduces the number of components, enabling miniaturization, weight reduction, and PCB cost savings. The multi-element resistive structure distributes the load, limiting surface temperature rise at the hottest points. The elongated terminal design mitigates thermal shock compared to standard terminal resistors. Difference in construction between Panasonic resistors and components from other manufacturers.
The structure with separated resistive elements distributes the load more effectively, resulting in improved thermal characteristics. Precise measurements illustrate this advantage using charts and thermal images: Reduced heating of resistors made using multiple resistive elements.Transistor Gate Drive (ERJP/ERJB Series)
Gate drive circuits in EV traction systems and inverters experience continuous power dissipation during fast switching, generating significant heat. Standard resistors often lack sufficient power handling and thermal management capability, leading to resistance drift and reduced lifetime. ERJPA/P0 and ERJB/D series resistors are high-power components with optimized heat dissipation and a stable thermal structure, ensuring reliable gate drive control.
ERJB/D series components can replace chip resistors to enable PCB miniaturization and reduce device weight. High surge resistance prevents failures and provides an optimal safety margin during design. High-power components with a special structure distribute the load evenly and prevent localized stress. Resistive element structure in ERJPA series components.Environmental Resistance: ERJU/ERJS Series
In outdoor or sulfur-containing environments—such as industrial AGVs and agricultural machinery—resistors with silver-based terminations are susceptible to sulfidation, leading to open circuits or degraded performance. Combined with humidity and high temperature, these factors significantly increase the risk of failure during long-term operation. The materials used in ERJU/ERJS series resistors minimize this risk.
Sulfur-resistance properties:
• prevents open circuits caused by sulfidation, increasing reliability;
• eliminates the need for PCB sealing, reducing costs;
• compliance with the AEC-Q200 standard;
• operating temperature range –55°C to 155°C.
Diverse ERJU series offerings include:
• high-precision components – ERJU*R series (0402 to 0805, 0.5% tolerance);
• compact high-power resistors – ERJUP series (0603 to 1206, 0.5 W in 0805);
• low-resistance versions – ERJU*S/Q series (0805, 0.1 Ω to 1 Ω, 10 mΩ to 1 Ω);
• high-power type (wide terminals) – ERJC series (1020 size, 2 W, 10 mΩ to 1 Ω). The photos and chart illustrate contact degradation caused by sulfidation and the resistance to harmful factors demonstrated by Panasonic components.
Summary
Panasonic consistently develops its portfolio based on innovative components for the transportation sector. The company delivers products that support vehicle electrification and automation, making mobility not only safer but also more efficient, better integrated, and more cost-effective to manufacture.
Below, as an appendix, is an overview of the described products along with their potential applications:
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