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.
