Periodic Reporting for period 1 - PowerDrive (Power electronics optimisation for next generation electric vehicle components)
Période du rapport: 2022-05-01 au 2023-10-31
POWERDRIVE is submitted in framework of the Horizon Europe’s Cluster 5 “Climate, Energy and Mobility” whose main focus is to “accelerate the twin green and digital transitions and associated transformation of our economy, industry and society with a view to achieving climate neutrality in Europe by 2050”.
Greenhouse gas neutrality of the energy and mobility sectors in combination with innovative solutions is at the very core of Europe’s strategy, in order to make “Europe the first digitally enabled circular, climate-neutral and sustainable economy through the transformation of its mobility, energy, construction and production systems” (Key Strategic Orientation “C”), and to contribute reaching a “strategic autonomy by leading the development of key digital, enabling and emerging technologies, sectors and value chains to accelerate and steer the digital and green transitions through human-centred technologies and innovations” (Key Strategic Orientation “A”).
The energy and mobility sectors are therefore required to become increasingly intertwined in the coming decades as it is outlined in the communication “A clean planet for all: A European strategic long-term vision for a prosperous, modern, competitive and climate neutral economy” adopted by the EU. In this framework, R&I is expected to provide a significant boost to this process by accelerating this transition, reducing associated costs, triggering environmental, economic and societal impacts, generating new employment opportunities, and promoting more sustainable use of natural resources. The timing of this transformation is of high importance as novel solutions need to rapidly find their way to the market; therefore, their development, implementation, commercialisation, and up-scaling needs to be fast enough to generate a concrete impact on society by 2030 and in order to contribute to meet the 2050 goals.
To comply with the described policy framework and meet the work programme requirements and EU policy goals, POWERDRIVE aims at developing a next generation, highly efficient, cost-effective, and compact power electronics solution that integrate a portfolio of technologies for multi-objective optimisation of electric powertrains
of battery electric vehicles (BEV). These integrated solutions can be applied to both low and high-performance vehicles, and they will be suitable for diverse types of electric vehicles (EV). The concept of POWERDRIVE is that all the experience and expertise of the project partners in the development of electric drivetrain components will be leveraged and lead into the integration of advanced power electronics solutions for an optimised powertrain. This concept brings additional opportunities to strengthen Europe’s supply chain in electromobility for road transportation and to achieve zero-emission road mobility.
The project's overall objective is to develop a functional ultra-compact, efficient, cost-effective, and integrated advanced power electronics solution for passenger BEVs through a portfolio of technologies that intends to achieve cost, loss, and size reduction in electric powertrains. Specifically, a 28% cost reduction, 35% loss
reduction, and power densities of around 26.4 kW/kg and 50.3 kW/litre are expected.
Greenhouse gas neutrality of the energy and mobility sectors in combination with innovative solutions is at the very core of Europe’s strategy, in order to make “Europe the first digitally enabled circular, climate-neutral and sustainable economy through the transformation of its mobility, energy, construction and production systems” (Key Strategic Orientation “C”), and to contribute reaching a “strategic autonomy by leading the development of key digital, enabling and emerging technologies, sectors and value chains to accelerate and steer the digital and green transitions through human-centred technologies and innovations” (Key Strategic Orientation “A”).
The energy and mobility sectors are therefore required to become increasingly intertwined in the coming decades as it is outlined in the communication “A clean planet for all: A European strategic long-term vision for a prosperous, modern, competitive and climate neutral economy” adopted by the EU. In this framework, R&I is expected to provide a significant boost to this process by accelerating this transition, reducing associated costs, triggering environmental, economic and societal impacts, generating new employment opportunities, and promoting more sustainable use of natural resources. The timing of this transformation is of high importance as novel solutions need to rapidly find their way to the market; therefore, their development, implementation, commercialisation, and up-scaling needs to be fast enough to generate a concrete impact on society by 2030 and in order to contribute to meet the 2050 goals.
To comply with the described policy framework and meet the work programme requirements and EU policy goals, POWERDRIVE aims at developing a next generation, highly efficient, cost-effective, and compact power electronics solution that integrate a portfolio of technologies for multi-objective optimisation of electric powertrains
of battery electric vehicles (BEV). These integrated solutions can be applied to both low and high-performance vehicles, and they will be suitable for diverse types of electric vehicles (EV). The concept of POWERDRIVE is that all the experience and expertise of the project partners in the development of electric drivetrain components will be leveraged and lead into the integration of advanced power electronics solutions for an optimised powertrain. This concept brings additional opportunities to strengthen Europe’s supply chain in electromobility for road transportation and to achieve zero-emission road mobility.
The project's overall objective is to develop a functional ultra-compact, efficient, cost-effective, and integrated advanced power electronics solution for passenger BEVs through a portfolio of technologies that intends to achieve cost, loss, and size reduction in electric powertrains. Specifically, a 28% cost reduction, 35% loss
reduction, and power densities of around 26.4 kW/kg and 50.3 kW/litre are expected.
The PowerDrive project, guided by NEVS specifications, began with a comprehensive study on the inverter and onboard charger. The partners conducted a preliminary selection of topologies, developing initial simulations and downscaled prototypes with integrated sensors.
Continuous refinements to thermal and electrical models play a crucial role in expediting the iterative optimization process within powertrain enhancement. Simultaneously, a comprehensive data collection initiative is underway, targeting EV users in Ireland and Belgium, with plans to extend to Sweden. This effort provides valuable insights beyond basic variables.
Objectives and status update
POWERDRIVE will be successful with the accomplishment of the overall and following specific objectives (SO):
SO.1: Optimise components (connectors, semiconductors, magnetics, cooling circuitry, etc.), and converters (traction inverter and OBC). Efficiency Power Density: 98.5% Efficiency (whole profile), Densities of 16.4 kW/kg and 24.9 kW/litre
Realization: Starting form de definitions of the specifications, a detailed state of the art has been developed focused on the analysis of different topologies for the inverter and OBC. Downsized prototypes are being tested to aid in the improvement of the models and the optimization process.
SO.2: Reduce the overall cost of the advanced power electronics solutions (inverter and OBC) using SiC and GaN components and advanced passive devices. Cost Density: 12.5 €/kW cost density in the set of Inverter and OBC
Realization: Demonstrators of the SiC power modules based on the inverter requirements and having integrated current and temperature sensors are expected to be available in the upcoming weeks. The development of the power modules is crucial to improve the efficiency and power density of the power train resulting in an overall reduction of the losses, volume, and cost of the solution.
SO.3: Integrate traction inverters and OBC into motors and batteries, respectively. Number of integrated systems: At least 1 integrated inverter-motor and 1 integrated OBC-battery
Realization: Two inverter concepts are being under evaluation, including the radial integration of the inverter with the electric machine. Customized busbars are under test and the electric and thermal models are being refined assisted by the data given by downscale prototypes.
SO.4: Model, simulate, and predict the operation of the advanced power electronics solutions under different load, charging, and real driving profiles to increase its reliability and quality. Accuracy Calculation Time: <5% deviation between simulation and testing Computational
performance which allows time-domain simulation for design purposes.
Realization: The collection of the data corresponding to the driving profiles has started and its analysis stage will start soon. Mechanical, electrical, and thermal models are under development by the different partners as an aid for the first prototyping of the inverter and the OBC. Its refinement is continuous process that will
accelerate with more experimental data.
SO.5: Integrate components and converters in one integrated powertrain platform. Number of platforms: At least 1 integrated platform for testing and demonstration
Realization: Later stage objective.
SO.6: Test, validate, and demonstrate the developed integrated advanced power electronics solutions implemented in a BEV platform. Number of tests. Measured efficiency and power density: At least 5 full sets of measurements and proof of the actual loss, cost, size, and weight reductions while the performance of the car is kept
high.
Realization: Later stage objective.
Continuous refinements to thermal and electrical models play a crucial role in expediting the iterative optimization process within powertrain enhancement. Simultaneously, a comprehensive data collection initiative is underway, targeting EV users in Ireland and Belgium, with plans to extend to Sweden. This effort provides valuable insights beyond basic variables.
Objectives and status update
POWERDRIVE will be successful with the accomplishment of the overall and following specific objectives (SO):
SO.1: Optimise components (connectors, semiconductors, magnetics, cooling circuitry, etc.), and converters (traction inverter and OBC). Efficiency Power Density: 98.5% Efficiency (whole profile), Densities of 16.4 kW/kg and 24.9 kW/litre
Realization: Starting form de definitions of the specifications, a detailed state of the art has been developed focused on the analysis of different topologies for the inverter and OBC. Downsized prototypes are being tested to aid in the improvement of the models and the optimization process.
SO.2: Reduce the overall cost of the advanced power electronics solutions (inverter and OBC) using SiC and GaN components and advanced passive devices. Cost Density: 12.5 €/kW cost density in the set of Inverter and OBC
Realization: Demonstrators of the SiC power modules based on the inverter requirements and having integrated current and temperature sensors are expected to be available in the upcoming weeks. The development of the power modules is crucial to improve the efficiency and power density of the power train resulting in an overall reduction of the losses, volume, and cost of the solution.
SO.3: Integrate traction inverters and OBC into motors and batteries, respectively. Number of integrated systems: At least 1 integrated inverter-motor and 1 integrated OBC-battery
Realization: Two inverter concepts are being under evaluation, including the radial integration of the inverter with the electric machine. Customized busbars are under test and the electric and thermal models are being refined assisted by the data given by downscale prototypes.
SO.4: Model, simulate, and predict the operation of the advanced power electronics solutions under different load, charging, and real driving profiles to increase its reliability and quality. Accuracy Calculation Time: <5% deviation between simulation and testing Computational
performance which allows time-domain simulation for design purposes.
Realization: The collection of the data corresponding to the driving profiles has started and its analysis stage will start soon. Mechanical, electrical, and thermal models are under development by the different partners as an aid for the first prototyping of the inverter and the OBC. Its refinement is continuous process that will
accelerate with more experimental data.
SO.5: Integrate components and converters in one integrated powertrain platform. Number of platforms: At least 1 integrated platform for testing and demonstration
Realization: Later stage objective.
SO.6: Test, validate, and demonstrate the developed integrated advanced power electronics solutions implemented in a BEV platform. Number of tests. Measured efficiency and power density: At least 5 full sets of measurements and proof of the actual loss, cost, size, and weight reductions while the performance of the car is kept
high.
Realization: Later stage objective.
A significant breakthrough was the testing of a novel busbar, improving radial integration between the inverterand EV motor for enhanced power density.