Scalable European Powertrain Technology Platform for Cost-Efficient Electric Vehicles to Connect Europe

Project Information

1000kmPLUS

Grant agreement ID: 824262

DOI

10.3030/824262

Project closed

EC signature date 3 October 2018

Start date 1 January 2019

End date 30 June 2023

Funded under

• SOCIETAL CHALLENGES - Smart, Green And Integrated Transport

Total cost

€ 6 736 651,38

EU contribution

€ 5 405 286,26

Coordinated by

INFINEON TECHNOLOGIES AG
Germany

Periodic Reporting for period 3 - 1000kmPLUS (Scalable European Powertrain Technology Platform for Cost-Efficient Electric Vehicles to Connect Europe)

Reporting period: 2021-07-01 to 2023-06-30

Summary of the context and overall objectives of the project

The need for scalable and brand-independent technology platforms for the key EV elements, like the invert-er-motor-transmission/gearbox (powertrain) and the battery, is evident. The project 1000kmPLUS addresses globally this point, to ensure the superiority of European automotive key technologies in terms of performance, scalability and costs for the 2ndand 3rdgeneration of EV.
The 1000kmPLUS project will build up a Mercedes-Benz EQ vehicle to demonstrate the project achievements by performing 3 challenges, representing real use cases for business as well as private travels.
To obtain breakthroughs in terms of energy efficiency, driving range, charging and costs, the 1000kmPLUS project develops a Scalable European Powertrain Technology Platform (SEPtop@SiC), which will define automotive powertrains for EV as commodities. It will use 1200 V SiC-MOSFETs to enable a 400 V/800 V cross-compatible inverter-motor-gearbox combo, scalable as a function of the required performance. Furthermore, ultra-fast charging up to 350 kW for everyday use will be demonstrated in an EV providing an initial driving range of 500 km based on its battery energy capacity.

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

The requirements regarding electrical powertrain, battery system, high power charging and the specifications for the overall system concepts and its integration have been elaborated and finalized. This also included the definition of BMS functionalities, general safety guidelines and mission profiles for determination of the battery’s optimum energy capacity.
An overall system architecture has been created. The different parameters of the components and interfaces, such as the mechanical interface, the connectors, the mounting points, the circuit boards and new EMC-Filter concepts have been defined, adapted and agreed within the consortium. A comprehensive vehicle simulation model has been derived to perform thermal and efficiency simulations of the whole car and to prepare a reliability evaluation of the E/E components. First power module prototypes were provided to do electrical and thermal characterizations. The concept of an ultra-fast charging battery system and an optimized routing algorithm were created to address the challenges of 1000kmPLUS with highest efficiency.
Further power modules were developed, assembled and tested. A power cycling lifetime model was created. The inverter together with the electric motor was adapted to fit the required operating voltage and current. Two motor test samples were successively built up and examined. New PCB design rules and gate drivers had to be implemented to adapt the inverter to the required voltage.
In respect to the embedded systems and computing algorithms, the basic structure of the thermal model was created and an inter-turn short circuit fault detection of the three-phase PMS motor was designed and tested on a small industrial motor. The previously specified BMS functionality has been implemented and is ready to be tested with the battery system. The communication interfaces between the BMS and the demonstrator car are defined. The Contraction Hierarchies and Multi-Level Dijkstra algorithms and their use for energy optimized routing system were investigated and a correct height profile is being prepared. A suitable energy consumption model is being prepared.
In regards to system integration and demonstrators, the planning activities for the demonstrator build up have already started. The new electric, thermal and mechanical system layouts have been analyzed and the integration of the new components is being investigated.
The project homepage was generated, giving an overview of the project, covering news and the first deliverables. The main dissemination activities will start in project period two.
As part of the project management and coordination kick-off meetings, technical workshops, phone conferences etc. have been organized and moderated. Within the risk management encountered challenges such as covid-19 have been addressed.

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)

The project 1000kmPLUS will ensure the superiority of European automotive key technologies in terms of performance, scalability and costs for the 2nd and 3rd generation of EV.1000kmPLUS will provide key arguments regarding the usability of the 2nd generation of EV to the Early Majority customers. Further, it will speed up the development and the ramp-up of series production of the 3rd EV generation.
The EV powertrain and battery technologies must now start to mature, in order to fulfil existential human mobility needs in terms of affordability and usability: this is the key to enter the early mass market. It assumes ramp-up of series production and affordability by economies of scale. The 1000kmPLUS project will enable, demonstrate and set up European mass production capabilities of EV key components (inverter, motor, transmission, SiC-MOSFET power modules, battery system) by Europe´s leading automotive companies. Further, it will build ECS value chains with focus on quality, safety, efficiency and costs.