Powertrain modularity

This deliverable provides updated specifications and requirements for the electrical, electronic, and thermal management subsystems of the RHODaS powertrain, building on those previously defined. It focuses on the design of a three-level, three-phase modular T-type converter based on SiC and GaN semiconductors, which must be compact to achieve the targeted gravimetric and volumetric power densities when mounted on top of the motor. The document details the converter’s dimensions, the integration of IMD components, and the semiconductor technologies under consideration.

Because commercially available GaN devices currently support only low voltages and currents, the deliverable proposes alternative strategies, such as using prototype GaN packs or parallelising multiple transistors, alongside a roadmap to address future design challenges. It also describes the supervision and monitoring strategies, including cloud-based functions, and defines the specifications for the thermal management system, with attention to environmental conditions and cooling requirements. The report concludes with a consolidated summary of the converter specifications, providing a reference for subsequent development and validation.

This report (D6.1) focuses on the integration and testing of two advanced powertrain components: the smart e-corner and the smart e-axle. The In-Wheel Motor (IWM) from ELA is integrated into the smart e-corner at TUIL and the baseline On-board Axial Flux Motor (AFM) is mounted on the powertrain test rig at USR. In parallel, a smart e-axle will be implemented at USR, while the dSpace Scalexio Rapid Prototyping system at TUIL will operate a virtual Vehicle model within a X-in-the-Loop (XiL) framework. This setup allows for distributed real-time simulation and control across both sites.

The experimental configurations will be equipped with comprehensive instrumentation—voltage, current, torque, temperature, and vibration sensors—to measure electrical and mechanical performance, thermal behaviour, and Noise, Vibration, and Harshness (NVH) characteristics. Control and monitoring will be coordinated through the dSpace platform and through a secure Virtual Private Network (VPN) connection between USR and TUIL.

The Horizon Europe projects EM-TECH and HighScape propose innovative solutions for electric traction machines and their WBG-based drives and components, to achieve higher energy efficiency, reduced volume and mass, as well as reduced cost. This paper outlines the main innovations of EM-TECH and HighScape, targeting a wide range of vehicle applications, including passenger cars and commercial vehicles. Specifically, EM-TECH deals with: i) modular designs of on-board axial flux machines (AFMs) for reducing the implementation costs of scalable centralised powertrains for electric axle (e-Axle) solutions; ii) in-wheel motors (IWMs) integrated with electric gearing, for expanding the high efficiency region of electric corner (e-Corner) powertrains; and iii) the use of permanent magnets deriving from recycling processes to improve sustainability. In parallel, HighScape targets the physical and functional integration of the power electronics of WBG-based traction inverters, onboard chargers, DC/DC converters, and electric drives for auxiliaries and actuators.