Abstract
A highly integrated electric drivetrain module with 157 kW peak power is presented, which incorporates novel technologies in the field of electric machines, power electronics and transmissions: 1. High-speed electric machine with six phases and injection mould polymer-bonded magnets; 2. High-ratio dual-speed transmission with double planetary gear set (Ravigneaux gear set); 3. Gallium nitride (GaN) power electronics with winding reconfiguration feature.The combination of these components in one single housing makes the drive module flexible to integrate and to combine with conventional or alternative propulsion technologies, thus allowing various hybrid and electric drivetrain topologies. All technologies are selected in accordance with mass production potential and can therefore have a high impact on the automotive market in the future. Currently, the drive module is under development; the first models will be assembled in winter 2019. The integration into a demonstrator vehicle in 2020 will prove the potential of many new technologies and the suitability for the automotive market.
Highlights
The electrification of passenger cars and light-duty vehicles—which are still responsible for around 20% of Europe’s greenhouse gas emissions [1]—will have an enormous effect on the reduction of greenhouse gas emissions
The Hybrid Synchronous Motor (HSM) was invented a few years ago, which is an evolution of the internal permanent magnet motor (IPM) [6]
The low-voltage Gallium Nitride (GaN) power device technology (650 V) provides a lot advantages compared to its Silicon (Si) and Silicon Carbide (SiC) competitors [11,12]
Summary
The electrification of passenger cars and light-duty vehicles—which are still responsible for around 20% of Europe’s greenhouse gas emissions [1]—will have an enormous effect on the reduction of greenhouse gas emissions. Combined with a cost reduction, a massive adoption of such transport in Europe and worldwide can be generated [4]. The focus is on cost reduction, low environmental impact, efficiency, and mass manufacturing readiness. The multiphase electric machine based on permanent magnets will be combined with the latest Gallium Nitride (GaN) power switches, advanced control with higher fault tolerance, and cooling features with reduced dimensions and a higher efficiency. It will be linked with a performant two-speed transmission, adapting new regenerative braking strategies.
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