HiPERFORM is a use case driven project and they represent relevant e-powertrain concepts with WBG technologies on different integration levels and validation of the concepts in relevant environments.
The partners in this use case will contribute to the specification and design of high power DC/DC and AC/DC modules, and topologies with SiC (high voltage) and GaN (low and medium voltage) semiconductors. Utilizing tailored advanced control algorithms, hardware with high dynamics up to 500 kHz and power density of up to 10kW/dm3, for usage in different test systems for batteries, e-motors and inverters, will be developed. The planned modules will be modelled and simulated, and prototypically built and integrated with an innovative cooling concept and passive elements to validate the system concepts. As a result of the project, a novel basis for highly efficient and dynamic test and emulation systems for testing current and future electrical components in electric vehicles and infrastructure will be validated. Resulting test systems will also be smaller in volume and have higher energy efficiency. Using similar technology for the e-powertrain and the testing systems will provide synergies between different industries.
Benchmarking performance of next-generation materials for power switches fabricated in GaN using an on-wafer test-bench, assessing performance merits for use of these materials in power subsystems for automotive applications.
To enable widespread adoption of WBG devices the cost of the components and long-term reliability needs to be improved. Reliability is of importance for the automotive sector, as a failure in the electronic system can compromise performance or in worst case safety of the vehicle and the passengers in it. However, currently no information is available on the potential and characteristics of GaN switches fabricated on the novel materials (poly-AlN & sputtered AlN templates). The work in this use case will be the first in-depth analysis and performance comparison. This information will pave the way for future adoption of novel materials by the European GaN industry and enable next generation performance (i.e. higher breakdown, lower cost and better reliability).
Also, at the end of the project a test bench will be available which can benchmark GaN switches in a manner which is relevant for automotive applications and which can give a quantification of maturity of a particular technology in automotive applications.
Demonstrate using hardware buildup the capabilities of SiC and GaN based power electronics targeting an automotive inverter application with special focus on Power modules
Today’s inverters for automotive applications are mainly based on well mastered bipolar IGBT technology but have their limits for inverter-switching frequency. SiC and GaN materials show a big potential to overcome these limitations for the power levels required in automotive traction applications (refer also to section 18.104.22.168). Actually, GaN technology is most suitable for Voltages below 650V and SiC for applications above. Result of this use case should be a next-generation, fully integrated power-module prototype, which is significantly reduced in size but maximized efficiency at high current rates and at the new standardized voltage level of 850V with super-fast switching speed in the module of up to 50V/µs. The target is to reach a specific power of 32 W/kg. The power range will be between 75kW and 300kW. The reliability requirements are at 10.000h of operation under specific cycling and typical automotive environmental conditions.
Demonstration of a complete powertrain conceived with capabilities of WBG materials, featuring high power density and high efficiency double SiC inverter.
The in-wheel motor technology is continuously gaining momentum in the automotive domain and offers some distinctive features such as performance, simplification of the powertrain and transmission layout, weight distribution along the vehicle, system costs. The starting point for the use case 4 relies on the solid industrial relationship between highly specialised companies (e.g. JAC, I&M, INFINEON and ELAPHE) in the field of innovative solutions for e-powertrain technology. The development of robust and affordable motor in wheel solutions will enable novel vehicle architectures, like heavy quadricycles, M1 passenger cars and novel urban vehicles such as automated pods, that will benefit most of the capabilities offered by motor in wheel in terms of design freedom for maximum usage of space and reduced footprint in the cities.
Demonstration of GaN-based power electronic converter for on-board charger, featuring more compacted system, high efficiency and high power density.
UC5 provides a strategy for making an on-board charger based on GaN technology, cost competitive and for accelerating the adoption of GaN-based components in the new charging systems. Compared with Si devices, GaN technology provides lower losses at higher frequencies. This benefit can facilitate the development of smaller devices with increased power density, which in turn affects the size and weight of the on-board charger. However, in order to clear the path for application of GaN-based on-board charger, research is needed on how to utilize the GaN converter in terms of system integration, safety, durability and performance. Thus, the design optimization of the new on-board charger will be done in WP5 based on GaN technology for more compact system and high power density.
This use case aims to provide a deeper understanding of the current state and potential impact of using GaN-based PE technologies in the on-board charging system.
In this use case, partners will contribute to the HiPERFORM project by exploring the technological possibilities for high power conversion electric vehicle chargers (up to 150kW), as opened up by the future availability of WBG power devices. Starting from the requirements specification candidates for the optimal power architecture and topologies based on WBG power devices will be identified. The key contribution beyond the state-of-the-art of high-power charger testing is to provide a charger system in the loop with new WBG technology that provides a higher efficiency (> 97%) with bi-directional operating mode for high grid quality.