Presentation of the final event for the three GV04 projects: ReFreeDrive, ModulED and Drivemode. Recordings available at https://www.youtube.com/playlist?list=PLUFRNkTrB5O-38psbMgeWAvzXQ5QWzNsk. ModulED aims at developing a new generation of modular electric engine based on buried-permanent magnet motor with reduced rare earth use, and electric drivetrain for various configurations of Full and Hybrid Electric Vehicles (including cost, environmental impact, efficiency, and mass manufacturing ready).

1. Horizon 2020
European Union funding
for Research & Innovation
THE NEXT GENERATION DRIVETRAINS
FOR FULLY ELECTRIC VEHICLES
Webinar 16-04-2021
Wouter Tits

2. Agenda
Introduction
Consortium
Project Overview
Objectives and Results
Demonstration
Project Impact
2

3. Introduction
European funded research project
Horizon 2020 research and innovation program
Budget: €7,2 million
Duration: 3 year (Oct 2017 – May 2021)
Next generation modular electric powertrains
Battery Electric Vehicles (BEV)
Full scale demonstration
High efficiency and low cost
3

4. Consortium
Design and Realization of GaN-based Inverter
Design and Realization of High-speed Motor
Study and Implementation of Regenerative Breaking
System optimization
Life Cycle Analysis
System Design and Integration
Study of Virtual Performance
Design of Multiphase Motor Control
Sizing of Transmission
4

5. Project Introduction
5
Cooling
E-motor
Transmission
Battery
Onboard
charging
Power
converter
Inverter

6. Technical Objectives
1. Multiphase high speed motor design with
reduced rare-earth magnets
2. Wide bandgap GaN inverter with
improved fault-tolerance
3. Dual speed transmission design
4. Optimized thermal management system
5. Improved regenerative braking strategy
6. Virtual assessment tool for sizing and optimizing
6
Efficient
Reliable
Low
carbon
footprint
Low
cost
Compact
& Modular

7. Objectives and Results
1. Multiphase motor design with reduced rare-earth magnets
Autonomy and safety
Efficiency and power density
Reduce content of rare earth magnets
7
High speed design up to 23000 rpm
E-motor torque of 160Nm
Power of 150kW
Higher potential

8. Objectives and Results
1. Multiphase motor design with reduced rare-earth magnets
High-speed motor design
Less rare earth magnets (-50%)
Good cost potential
High power density (26kW/l)
High efficiency over a broad range (97,4%)
FLW (Formed Litz Wire) stator design
6-phase Buried Permanent Magnet Motor
Increases fault-tolerance
Lower current and voltages required
8

9. Objectives and Results
1. Multiphase motor design with reduced rare-earth magnets
Direct Injection of the bonded magnets into the rotor stacks
Mold designed, combining mechanical and magnetic features
9
Lower remanence
Cost (Price/kg)
Not standard yet
Freedom in shape
Completely filled cavities
Low electrical conductivity
No Heavy rare-earths, no Ga
Direct Injected Magnets

10. Objectives and Results
1. Multiphase motor design with reduced rare-earth magnets
Direct Injection of the bonded magnets into the rotor stacks
Mold designed, combining mechanical and magnetic features
Adapted rotor design
Good magnetic alignment of the compound
Perfect match with simulation
10

11. Objectives and Results
11
Specifications
ModulED Motor ModulED Motor BMW i3 Unit
NdFeB Injected NdFeB
Peak current 6ph 225 225 410 Arms
Winding type FLW FLW PIW -
Number of phase 6 6 3 -
Nominal speed 8600 8600 5000 rpm
Max. motor speed 22500 22500 11400 rpm
Peak torque 160 156 250 Nm
Peak power 157 158 131 kW
Nominal battery voltage 320 320 360 VDC
Stator outer diameter 176 176 242 mm
Stator inner diameter 118 118 180 mm
Active length 179 179 130 mm
Magnet weight 1.32 1.73 2.02 kg
Reference DC voltage 360 360 360 VDC
Peak power @ 360VDC 177 178 131 kW
Magnet weight per power 7.5 9.7 15.4 g/kW
Magnet amount reduction to reference motor -52% -40% 0% -

12. Objectives and Results
2. Wide bandgap GaN inverter with improved fault-tolerance
High efficiency and good integration capability
Fast switching performance (<10ns)
Low switching & conduction losses (13x Si, 6x SiC)
High power density
Limited current capability of 120ARMS
Unconventional topology:
12
6 independent phases
reconfigurable machine
6 phases inverter
Full bridge
Battery
X6 => 36 GaN devices
Torque/Speed
DC-
Link
x12
…
…
Inverter Scope
12
connections
State-of-Art ModulED
Si / SiC GaN
3 phases 6 phases
Half bridge Full bridge
Star Independent

13. Objectives and Results
2. Wide bandgap GaN inverter with improved fault-tolerance
Serial bidirectional switches: 6phase 3phase
13
6 independent phases
reconfigurable machine
6 phases inverter
Full bridge
Battery
X6 => 36 GaN devices
Torque/Speed
DC-
Link
x12
…
…
Inverter Scope
12
connections

14. Objectives and Results
2. Wide bandgap GaN inverter with improved fault-tolerance
Serial bidirectional switches: 6phase 3phase
Modular setup
Improve operational continuity
Lower service cost
Extend full torque range
Improve thermal performance and lifetime
14

15. Objectives and Results
2. Wide bandgap GaN inverter with improved fault-tolerance
Integration architectures
Stray capacitance reduced by factor 3
Lower oscillations between capacitor stages,
Improving the voltage stability across GaN devices.
High peak efficiency close to 99%
15
Requested torque not reached
Thermal limitation inside the die
Current limit of 90ARMS
➔ Worlds first automotive inverter
with this output power

16. Objectives and Results
3. Dual speed transmission design
High speed dual ratio transmission for optimal performance
Topology selected based on cost, size & efficiency
Increased transmission efficiency
Optimizing gear geometry
Improved bearing configuration
16
Out
M
1 2

17. Objectives and Results
3. Dual speed transmission design
Good efficiency for both reduction ratios
First gear: 97,4% Second gear: 96,7%
17

18. Objectives and Results
3. Dual speed transmission design
Low loss passive lubrication system
Efficient low-cost actuation system
Integrated housing design
Full system power density >3,25kW/l
18
GaN Inverter
Battery connection
Output shaft
Actuation system
Ravigneaux
planetary set
E-machine
Pinion Gear
Crown Gear
Coolant inlet
Coolant outlet
Coolant divider
Cooling Jacket
Inverter Cooling

19. Objectives and Results
4. Optimized thermal management system
Optimized cooling design for e-machine
Coolant channel sizing
Thermal contact resistances
End winding potting
19

20. Objectives and Results
4. Optimized thermal management system
Optimized cooling design for e-machine
Coolant channel sizing
Thermal contact resistances
End winding potting
Optimized cooling design for GaN inverter
Integrated cooling block located around output shaft
Geometric design space exploration
Anisotropic thermal interface material
20

21. Objectives and Results
4. Optimized thermal management system
Optimized cooling design for e-machine
Coolant channel sizing
Thermal contact resistances
End winding potting
Optimized cooling design for GaN inverter
Integrated cooling block located around output shaft
Geometric design space exploration
Anisotropic thermal interface material
Optimized integrated cooling system design
Optimized fluid distribution & temperature homogeneity
Thermal optimization
21

22. Objectives and Results
5. Improved regenerative braking strategy
Regenerative Braking Control:
Energy recuperation Vehicle stability
Include cornering in the design
Brake Energy Management:
Brake force distribution adaptive to driving conditions
Significant energy recuperation gains achieved
Maintains drivability and safety
22
Conventional
ModulED A
ModulED B
76%
83%
94%

23. Objectives and Results
5. Improved regenerative braking strategy
Regenerative Braking Control:
Energy recuperation Vehicle stability
Include cornering in the design
Brake Energy Management:
Brake force distribution adaptive to driving conditions
Significant energy recuperation gains achieved
Maintains drivability and safety
Torque Reversal manoeuvre
Brake-in-turn manoeuvre
23
Driveshafts Torque Longitudinal Acceleration
Steering Wheel & Brake Demand Inputs Yaw Rate

24. Objectives and Results
6. Virtual assessment tool for sizing and optimizing
24
Efficiency
Cost
Mass
Safety
Lifetime
NVH
?
Vehicle
Demands
Holistic Powertrain Concept Design
Selection of Powertrain Concept
Drive Module and Vehicle Results
Holistic powertrain
design approach
Consideration of
component
interdependencies
Overall evaluation of
drive modules on
vehicle level
Powertrain
Concept

25. Powertrain validation
Module assembly and conditioning
Powertrain validation tests
Full functional operating range
Efficiency evaluation
25

26. Powertrain validation
Module assembly and conditioning
Powertrain validation tests
Full functional operating range
Efficiency evaluation: 92,7% in Gear1 and 91,7% in Gear2
26

27. Powertrain validation
Module assembly and conditioning
Powertrain validation tests
Full functional operating range
Efficiency evaluation
Combined efficiency map
27

28. Powertrain validation
Module assembly and conditioning
Powertrain validation tests
Full functional operating range
Efficiency evaluation
Combined efficiency map
Noise & Vibration
evaluation ongoing
28

29. Vehicle validation
WLTP Energy consumption
Consumption of 134Wh/km
Improvement with GaN-inverter
up to 2% at high speed
True potential of dual speed
29

30. Vehicle validation
WLTP Energy consumption
Consumption of 134Wh/km
Improvement with GaN-inverter
up to 2% at high speed
True potential of dual speed
Expert drive
Good to very good drivability
Satisfactory performance on NVH
Shifting control algorithm
30

31. Demonstration
31

32. Project impact
Project has investigated research topics such as
Multiphase high speed motor design with reduced rare-earth magnets
Injection magnet motor technology
Wide bandgap GaN inverter with improved fault-tolerance
High speed dual speed transmission design
Optimized thermal management system
Improved regenerative braking strategy
Virtual assessment tool for sizing and optimizing
Market integration
Motor and transmission: TRL>6
GaN inverter: TRL<6
32
Efficient
Reliable
Low
carbon
footprint
Low
cost
Compact
& Modular

33. Horizon 2020
European Union funding
for Research & Innovation
THE NEXT GENERATION DRIVETRAINS
FOR FULLY ELECTRIC VEHICLES
Thank you for your attention
Wouter.Tits@punchpowertrain.com
https://moduled-project.eu/