Anagrafe della ricerca

Current mass-market electric vehicles (EVs) operate at a voltage level of 400V. In the meantime, there is however a clear trend to increase the voltage level towards 800V, which is expected to become the standard by 2027-2030. Doubling the voltage level allows for higher power charging and an associated reduction of the necessary charging time. The current levels in the system are also lowered, hence imposing less demanding thermal loads. To further strengthen the market position of future EVs, ongoing investigations are already targeting integrated concepts beyond 800V, with future operating voltages expected to be in the range of 1200V. Such concepts should be highly-efficient, affordable, safe, sustainable and compatible with current technology. In this context, GEN1200 will focus on modular and scalable 1700V SiC-based power electronics solutions for 1200V powertrains, encompassing architectures for enhanced charging while ensuring compatibility with existing infrastructure, and highly-efficient and highly-integrated electric axles for C-segment vehicles, which can be extrapolated towards different EV configurations and classes. The system will be holistically optimized to maximally exploit the opportunities enabled by higher voltage levels. The project activities will result in: (i) innovative 1700V SiC power electronics systems with multiple use of components, e.g., the traction inverter will also embed the functionality of interleaved boost converter providing backwards compatibility with any 400V or 800V DC charging infrastructure, as well as the one of 22 kW on-board AC charger; (ii) 1200V electric axle solutions with electrical, thermal and mechanical integration of the power electronics, electric machine, mechanical transmission, and a selection of auxiliaries; (iii) ultra-fast 350 kW charging of novel 10C battery modules with integrated electronics and modular wireless management solutions for 1200V battery packs. All activities will be supported and enabled by the development of digital twins of component and systems, as well as tailored control solutions targeting 1200V powertrains, e.g., for the adjustable modulation of the adaptive gate drivers of the post-800V power electronics, for reducing power losses in partial load conditions, and life cycle analysis. Innovative testing methodologies, combining classical component and system characterization, x-in-the loop, and experimental vehicle assessment, will cover the wide range of relevant aspects, including efficiency, durability, electromagnetic compatibility and interference (EMC/EMI), as well as charging performance and sustainability. GEN1200 will leverage the complementary competences and exploitation potential of 3 academic partners, 1 RTO, 2 SMEs and 2 large industrial players to co-define the future of sustainable road transport. In summary, GEN1200 will establish new knowledge and industrial leadership in key digital, enabling and emerging technologies, and, therefore, directly contribute to Europe’s Key Strategic Orientations C and A as well as actively support the transformation towards the next generation of zero tailpipe emission road mobility (2Zero).