The specific milestones their status is updated, the deliverables outlined in the report affirm the project's adherence to schedule. Minor delays, detailed in the report's conclusion, have been addressed to ensure continued project momentum.
Objectives and status update
POWERDRIVE will be successful with the accomplishment of the overall and following specific objectives (SO):
Overall Objective: 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.
Efficiency Power Density Cost: 28% cost reduction, 35% loss reduction, and power densities of around 26.4 kW/kg and 50.3 kW/litre
SO.1: Optimise components (connectors, semiconductors, magnetics, cooling circuitry, etc.), and converters (traction inverter and OBC) (WP1-7)
Efficiency Power Density: 98.5% Efficiency (whole profile), Densities of 16.4 kW/kg and 24.9 kW/litre
Realization: SA detailed state-of-the-art review has been developed, focusing on the analysis of different topologies for the inverter and OBC. Downsized prototypes are currently being tested to support improvements in the models. Final prototypes are in the development phase and will meet the power density requirements. Simulations and tests have been carried out to reduce size and/or increase the efficiency of multiple critical components, including DC-link capacitors, transformers, inductors, busbars, and the cooling solution.
SO.2: Reduce the overall cost of the advanced power electronics solutions (inverter and OBC) using SiC and GaN components and advanced passive devices (WP1-7)
Cost Density: 12.5 €/kW cost density in the set of Inverter and OBC
Realization: A study on the reduction in size and cost of DC-link capacitors is conducted and published.
SO.3: Integrate traction inverters and OBC into motors and batteries, respectively (WP1-3)
Number of integrated systems: At least 1 integrated inverter-motor and 1 integrated OBC-battery
Realization: Two inverter concepts are build, including the radial integration of the inverter with the electric machine. Customized busbars are tested and produced, and the electric and thermal models are developed, and control strategy is under development to optimize the losses and lifetime
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 (WP7-8)
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 been completed and its analysis stage is started.
For fast simulation of the core losses a full order model (FOM) and a reduced order model (ROM) are created.
SO.5: Integrate components and converters in one integrated powertrain platform (WP1-3).
Number of platforms: At least 1 integrated platform for testing and demonstration
Volvo has detailed the characteristics of the testing platforms in D1.2 and is currently holding regular meetings with the partners involved, in order to align the practical aspects of performing the tests at Volvo’s facilities in Gothenburg.
SO.6: Test, validate, and demonstrate the developed integrated advanced power electronics solutions implemented in a BEV platform (WP1 & WP9)
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: Test specifications have been defined see deliverable D1.2. Volvo has also initiated the planning and booking of the final event to demonstrate the work carried out at their facilities.
