Digitalization of Power Electronic Applications within Key Technology Value Chains

Project Information

PowerizeD

Grant agreement ID: 101096387

DOI

10.3030/101096387

Project closed

EC signature date 1 December 2022

Start date 1 January 2023

End date 31 December 2025

Funded under

• Digital, Industry and Space

Total cost

€ 73 296 965,25

EU contribution

€ 18 267 433,19

Coordinated by

INFINEON TECHNOLOGIES AG
Germany

Periodic Reporting for period 2 - PowerizeD (Digitalization of Power Electronic Applications within Key Technology Value Chains)

Reporting period: 2024-01-01 to 2024-12-31

Summary of the context and overall objectives of the project

The overarching goal of PowerizeD is to develop breakthrough technology for digitized and intelligent power electronics to enable sustainable and resilient energy generation, transmission and applications. PowerizeD enhances the level of mechanical and electrical integration of the control, the driver and the switch functionality in one component and allows, for the first time, a joint optimization of all power switch functionalities. The usage of new circuit models, advanced control strategies and artificial intelligence enables the integration of parts of the control loop, leading to a robust and reliable operation.
To facilitate data sharing along the value chain, PowerizeD drives the novel approach of Federated Learning. This collaborative optimization of specific compact models and neural networks provides a methodical approach to an intrinsically encrypted transfer of confidential and proprietary data. In parallel, PowerizeD allows for the first time the usage of digital twins based on detailed electrical physical models such that power electronic devices can be digitally monitored and controlled in real time. Unlike other projects focusing on competence and technology with limited effort on demonstration, this project will start from vital societal needs, by identifying and analysing the key universal technology challenges in broad application scopes.
Major effort will be spent on cross-domain research and innovation. The newly developed key technologies will be demonstrated and evaluated in many universally applicable results. To realize this ambition, a large project consortium is formed to incorporate the required competencies and resources. 21 Large Entities, 16 Small Medium Enterprises and 24 research partners from 13 countries – representing the entire value chain from materials to “systems of systems” – strive to demonstrate the applicability of these innovative approaches to multiple industrial domains. Among the direct objectives are a 25% reduction of power losses, a device and system lifetime increase of 30%, a chip size reduction of at least 10% and a shortening of the design time by 50%. Hereby, PowerizeD addresses the three megatrends Independence, Sustainability and Digitalization, opening pathways to massive economic and societal benefits for the EU.

Work performed from the beginning of the project to the end of the period covered by the report and main results achieved so far

PowerizeD will bring additional intelligence to power electronics modules and components: The increased intelligence (control) will allow a robust and reliable operation and, at the same time, utilize a robustness margin for increasing the usable function. This will bring integration to the next level. PowerizeD will solve the actual issue of digitalisation, namely the conflict between public availability and exchange of confidential proprietary data sets. PowerizeD will drive and implement the novel approach of Federated Learning for collaborative optimisation of detailed compact models and neural networks. Federated Learning also allows to feed the currently confidential field data in an anonymous way into the design loop, using optimised models for advanced development and simulation tools. This, together with the possibility of automatic code generation and collaborative use of generalized digital twins during the whole development life cycle will allow reducing the development time significantly. In parallel, PowerizeD will allow for the first time the usage of detailed electrical physical models, to be used in digital twins of real-time-digitally monitored and controlled power electronic devices. For this, PowerizeD will focus on the semiconductor and advanced driver level, but also will set a minor focus on the optimised development path of inductive components and the reliability of integrated ceramic capacitors. Furthermore, PowerizeD will investigate necessary availability of materials and the influence on sustainable usage. A significant improvement in lifetime and robustness enabled by PowerizeD leads to longer lasting products, ultimately resulting in an optimized usage of material resources and less waste. Finally, the technological advances investigated and demonstrated in PowerizeD provide a considerable head start for the participating organisations and will lead to a globally competitive and resilient European industry in the area of power electronics. Overall, by its unique approach on Cross Application & Domain Topics (CDT) and Use Cases (UC), PowerizeD will be a game changer, focusing on the intelligence for power electronics applications.

Progress beyond the state of the art and expected potential impact (including the socio-economic impact and the wider societal implications of the project so far)

PowerizeD aims at highly ambitious goals to advance power electronics in Europe.
Ambition 1: Boost the Design Productivity
Bringing more digitalization and advanced AI methods into power electronic systems is the most crucial contribution of PowerizeD for greatly accelerating the design of power electronics. With digitalisation, advanced design tools can be used, allowing the rapid implementation of sophisticated methods and control strategies in a very short time. Moreover, substantially more testing can be carried out already before implementation. Overall, the design time will be reduced by 50%.
Ambition 2: Achieve highest Quality with affordable Efforts
We all request power electronic systems that are robust in all operation conditions and offer excellent lifetime. PowerizeD will achieve this by advancing design-for-reliability, including virtual testing, using digital twins, and combining this with sophisticated prognostic health management, focusing on the critical components. The broad introduction of digitalisation including intelligence, e.g. federated learning, is what sets PowerizeD apart. Contrary to other approaches, PowerizeD does not ask for substantial overdesign anymore and will provide highly robust and long-living power electronic systems, while at the same time achieving a chip size reduction of 20%.
Ambition 3: Provide attractive Power Electronics at highly competitive Costs
Attractive power electronic systems are small and efficient. With PowerizeD, it will become possible to achieve these goals that at highly competitive cost. This is enabled by extensive digitalisation and integration of intelligence. They give rise to advanced driving techniques and control methods. This is complemented by a new level of functional integration. We expect excellent efficiencies up to 50% above the SotA and volume reductions reaching 30% wrt SotA. Since digitalization is the key for smarter design including better exploitation of today’s components, costs will remain very attractive.
Ambition 4: New Products with more/enhanced Functionality and higher Level of Optimisation
The overarching ambition of PowerizeD is to bring forward digitalisation as key enabler to fully benefit from advancements on all levels - design, operational margin and individualized gate drivers. New options to partition functionality will also arise from that, leading to power electronic products with much more flexibility and eventually greater functionality.

Consortium Map