Powertrain modularity

This document provides a comprehensive report on the activities related to the experimental validation of lab-scale power converter prototypes. It includes an analysis of the current standards for power converter testing, drawing on publicly available sources and the expertise of RHODaS partners.

The document also proposes a detailed test plan for High Power Converters (HPC), which are based on Low Power Converter modules. This plan encompasses electrical tests for both Low Voltage (LV) and High Voltage (HV) parts, as well as environmental, mechanical, and safety tests. Additionally, the document reports on laboratory tests to verify basic parameters of Low Power Converters (LPC), such as efficiency, distortion, and Common Mode Voltage (CMV).

The analysis highlights the absence of comprehensive standards for inverter testing, necessitating the search for relevant documents from various testing fields. Due to the high voltage levels considered in the DC/AC converter, of at least 1000 VDC Bus, it is necessary the adaptation of research methodologies in cases where direct references are lacking. This process requires substantial knowledge and experience in test systems and application of standards.

The conclusions drawn from these activities are expected to support future design, optimization and recommendations, focusing on further improvements in power converters and the use of standards specifically adapted for them in automotive applications.

The Dual Active Bridge Converter topology is widely recognized for its high power density in high-power applications, enabling soft switching and achieving high efficiencies in both buck and boost operation modes. However, under conventional phase-shift modulation, operation at light or no load results in hard-switching and high effective currents, leading to increased overall losses, one of its main drawbacks. These issues have been primarily addressed by implementing complex modulation strategies, leveraging from the multiple degrees of freedom in the control of the converter power, particularly the inner and outer shift angles of its bridges. Contrary to the traditional approach, this work proposes the modulation of the series inductance of the DAB converter by implementing a switched inductor, aiming for a simplified modulation strategy. The proposed method effectively achieves zero current under no-load conditions and significantly reduces effective currents at light loads compared to the traditional phase-shift modulation approach. Although an in-depth comparison with other modulation schemes is required, this work represents a stepping stone in the analysis of the topology and the comprehension of its trade-offs.

This deliverable reports the selection of the optimum power devices for implementing the SCAPE high-voltage switching cells, after a literature review and commercial availability check. In addition to suitable electrical characteristics, the selection of candidates considered the suitability and availability of bare-die components for their subsequent chip embedding process. Two SiC MOSFET references have been selected and samples have been obtained for an initial test campaign (GeneSiC G4R12MT07. 750V – 12 mΩ and Wolfspeed CPM3-0650-0015A. 650V – 15 mΩ). For the development of the low-voltage switching cells of the auxiliary SCAPE converters, GaN HEMTs from EPC will be selected. The deliverable also includes a prospective and literature review about power device emerging technologies. 

Gallium nitride (GaN) and silicon carbide (SiC) semiconductors can improve the power converters used in electric vehicles. These devices offer significant advantages due to their ability to operate at high switching frequencies while maintaining high efficiency. This paper presents a comprehensive comparison of modulation techniques for hybrid T-type converters that use SiC and GaN semiconductors. The analysis compares modified sinusoidal pulse-width modulation (M-SPWM), double-signal pulse-width modulation (DSPWM), and carrier-based pulse-width modulation (CB-PWM) techniques in terms of efficiency and DC bus balancing capabilities. The study examines the normalized voltage ripple and losses on the DC bus utilizing MATLAB/Simulink and PLECS. The simulation results indicate that DSPWM and CB-PWM hold promise as viable alternatives to the traditional M-SPWM technique for electric mobility applications, particularly when the power converter operates at high switching frequencies.

During the last 15 years, the automotive domain has been subject to several disruptive transformations, impacting the full supply chain and enabling the uptake of new services and solutions around road-based passenger mobility and freight transportation. Electrification, CCAM, and SDV are leading to a total redesigning of the vehicle and its components, and very equally to a rethinking of how to deliver value. While software is playing a key role for value creation, it strongly relies on innovative mechatronics platforms and smart powertrain and chassis components as foundation for the SDV of the future. Target of this paper is to introduce the results of the three complementary research projects HighScape, EM-TECH, and SmartCorners, with the focus to deliver consistent innovation along the three following pillars: (a) electrified powertrain and chassis components, (b) vehicle platform and highly integrated corner solutions, and (c) novel control algorithms making use of smart components.

The RHODaS Webinar Series presents four interconnected sessions exploring the latest European research on next-generation electric powertrain technologies. Hosted by the RHODaS consortium under the Horizon Europe framework, funded by ‪the European Commission‬ and as part of the E-VOLVE Cluster, the webinar series will feature insights from the RHODaS, SCAPE, ‪Maxima‬ and EM-TECH projects, bringing together leading experts in power electronics, digital systems, and sustainability. Each webinar focuses on a specific technological domain critical to the electrification of transport — from component design and thermal management to digital intelligence and circularity. Together, they illustrate how European research is transforming electric mobility through efficiency, reliability, and environmental responsibility. 

This opening session delves into the design of hybrid wide bandgap converters and modular architectures for electric vehicles. Presentations from RHODaS and SCAPE will discuss innovative SiC/GaN topologies, design challenges such as parasitic inductances and layout constraints, and scalable approaches for vehicle power conversion systems.

The transition to e-mobility is disrupting the automotive market. To facilitate this transition, the European Commission with the support of the 2ZERO partnership is calling for experts to engage in collaborative R&D programs, and develop pre-competitive solutions and methodologies supporting the uptake of e-mobility. The target of this paper is to provide an overview of the granted European projects running under the umbrella of the E-VOLVE cluster, illustrating the complementarity of the different initiatives as well as their coverage of the main priorities as defined by ERTRAC. The focus is set on the targets and outcomes of the projects HiPE, HighScape, RHODaS, SCAPE, EM-TECH and Multi-Moby, addressing innovative components (power electronics, e-motors), advanced control strategies, and circularity for safe, efficient, affordable and sustainable e-mobility.