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Power Electronics

[Due to the increasing size of the archives, each topic page now contains only the prior 365 days of content. Access to older stories is now solely through the Monthly Archive pages or the site search function.]

Siemens and BAIC form JV to produce high efficiency electric powertrain systems for NEVs

April 21, 2014

Siemens AG and Beijing Automotive Industry Holding Co., Ltd. (BAIC), one of the major Chinese carmakers, signed a joint venture agreement at the 2014 Beijing International Automotive Exhibition and outlined their plan to utilize Siemens’ electric drive train components in a range of BAIC new energy vehicles (NEVs).

The JV, Beijing Siemens Automotive E-Drive System Co., Ltd., will manufacture components for the electric drivetrain including power-electronics and electric motors. The new electric drivetrains consist of a safer and higher power density inverters and highly energy efficient motors. Prototype and small volume production will start in 2014, followed by mass production in a new Beijing-based factory in 2015. The production volume is planned to be more than 100,000 units per year with upside potential.

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First “MotorBrain” prototype shown; lightweight electric motor system with no rare earth metals

April 11, 2014

MotorBrain prototype. Integrated unit is on the left, the motor core is at the right. Click to enlarge.

The four partners in the European research project ”MotorBrain”—Infineon Technologies, Siemens, the Institute of Lightweight Engineering and Polymer Technology at the Technische Universität (Technical University) Dresden and ZF Friedrichshafen—are presenting their first prototype of a lightweight electric motor system that requires no rare earth metals.

The €36-million (US$50-million) MotorBrain effort is one of the largest single European research projects in the area of electromobility. The MotorBrain prototype integrates the motor, gear drive and inverter. The prototype is three-quarters the size of models from 2011, the year when MotorBrain began; the prototype now being presented could fit in a conventional-sized laptop or notebook backpack.

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3-year, $75.7M eRamp power electronics research project launches at Infineon

April 02, 2014

The three-year research project “eRamp”, intended to strengthen and expand Germany and Europe as centers of expertise for the manufacture of power electronics, launched at Infineon Technologies in Dresden. Twenty-six research partners from six countries are participating. Infineon, a global market leader in power semiconductors, is leading the €55-million (US$75.7-million) project.

Power electronics—the electronic components and their power semiconductors—help keep the loss of electrical energy as low as possible and help minimize power consumption in a wide variety of applications, including hybrid and electric drive systems. eRamp research activities will focus on the rapid introduction of new production technologies and further exploration of chip packaging technologies for power semiconductors.

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Zytek lightweight electric powertrain for Yamaha’s MOTIV.e city car concept

February 21, 2014

Zytek’s lightweight 25kW powertrain drives the Yamaha MOTIV.e through a Vocis single ratio transmission. A further development of the electric machine will deliver more power and torque from the same compact package. Click to enlarge.

Yamaha’s new MOTIV.e city car concept, shown at the Tokyo motorshow, is powered by an electric drive system from Zytek that employs a range of new design approaches to minimize the cost, weight and size of the powertrain while maximizing the performance and range. By supplying a number of core high-voltage components as an optimized system, Zytek is also minimizing the time required for vehicle development.

MOTIV.e comes from the partnership between Yamaha and Gordon Murray Design, using Murray’s iStream manufacturing technology; Murray has partnered in the past with Zytek on the T.27 City Car—the technology basis for the MOTIV.e. (Earlier post). Zytek Automotive, a specialist EV/HEV/fuel cell engineering consultancy, is a subsidiary of Continental, the global powertrain, chassis and interior products supplier.

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Toyota recalling about 701,000 Gen 3 Prius vehicles in US over software issue in inverter assembly

February 12, 2014

Toyota Motor Sales, USA, Inc., is advising the National Highway Traffic Safety Administration (NHTSA) of plans to conduct voluntary safety recalls of approximately 701,000 Model Year 2010-2014 Prius vehicles to update the motor/generator control ECU and hybrid control ECU software. This is part of a global recall for the issue.

According to the information Toyota is providing Prius customers in the US, the problem resides in the Intelligent Power Module (IPM), which is inside the Hybrid Inverter Assembly. The inverter converts high-voltage direct current (DC) stored in the high-voltage (HV) battery into high-voltage alternating current (AC) for the motor/generator. It also converts AC into DC during regenerative braking for storage in the HV battery. According to Toyota, due to problems with the software, certain transistors in the IPM could become damaged when operating the vehicle under high-load driving conditions, such as accelerating during highway driving.

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DOE to award $49.4M for advanced vehicle technologies research; meeting Tier 3 emissions

January 22, 2014

The US Department of Energy (DOE) will award $49.4 million to projects to to accelerate research and development of new vehicle technologies. The new program-wide funding opportunity (DE-FOA-0000991) (earlier post), was announced by Energy Secretary Ernest Moniz at the Washington Auto Show.

The funding opportunity will contains a total of 13 areas of interest in the general areas of advanced light-weighting; advanced battery development; power electronics; advanced heating, ventilation, air conditioning systems; advanced powertrains (including the ability to meet proposed EPA Tier 3 tailpipe emissions standards); and fuels and lubricants. These areas of interest apply to light, medium and heavy duty on-road vehicles.

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DOE issues $10M incubator FOA for batteries, power electronics, engines, materials, fuels and lubricants

January 18, 2014

The US Department of Energy (DOE) Office of Energy Efficiency and Renewable Energy’s (EERE’s) Vehicle Technologies Office (VTO) issued an Incubator Funding Opportunity Announcement (FOAs) for a total of approximately $10 million. (DE-FOA-0000988)

EERE is focused on achieving well‐defined mid‐to‐long term clean energy goals for the US, and in that context has established multi‐year plans and roadmaps, with a concomitant focus of the majority of its resources on a limited number of “highest probability of success” pathways/approaches to ensure that the program initiatives are supported at a critical mass (both in terms of dollars and time) for maximum impact. While this roadmap‐based approach can be a strength, it can also create challenges in recognizing and exploring unanticipated, game changing pathways/approaches which may ultimately be superior to the pathways/approaches on the existing roadmaps.

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President Obama announces new $140M public-private manufacturing innovation institute focused on power electronics

January 16, 2014

President Obama announced the selection of a consortium of businesses and universities, led by North Carolina State University, to lead a manufacturing innovation institute for next-generation power electronics. (Earlier post.)

More specifically, the Next Generation Power Electronics Institute is focused on making wide bandgap (WBG) semiconductor technologies cost-competitive with current silicon-based power electronics in the next five years. Compared to silicon-based technologies, wide bandgap semiconductors can operate at higher temperatures and have greater durability and reliability at higher voltages and frequencies—ultimately achieving higher performance while using less electricity.

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CAR report quantifies automotive’s position as a leading high-tech industry

January 08, 2014

Percentage of Global R&D Spending by Industry, 2013. Source: Booz & Company “Global Innovation”; Battelle R&D Magazine; Center for Automotive Research 2012. Click to enlarge.

A newly-released report by the Center for Automotive Research (CAR) concludes that the automotive industry is not only “high-tech,” it is frequently a leader in technological developments and applications. The report, supported by the Alliance of Automobile Manufacturers, measures the technological nature of today’s auto industry and compares it to other sectors of the economy often viewed as technologically advanced.

The report authors acknowledge the difficulty of defining “high-tech” in an ever-changing economic environment. After reviewing of the works of several researchers and government agencies, CAR developed a working definition to differentiate high-tech industries from other sectors. Broadly, high-tech industries generally have the following characteristics:

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DOE to issue FY14 Vehicle Technologies program-wide funding opportunity announcement

December 20, 2013

The Department Of Energy (DOE), Office of Energy Efficiency and Renewable Energy (EERE) intends to issue, on behalf of its Vehicle Technology Office (VTO), a program-wide Funding Opportunity Announcement (DE-FOA-0000991) for fiscal year 2014 on or about January 2014. The advance notice (DE-FOA-0001053) is to alert interested parties of the coming FOA.

The areas of interest outlined in the notice of intent (NOI) fall into two broad categories: technologies to advance plug-in electric vehicles; and technologies to improve fuel efficiency, including dual-fuel, fuel properties (e.g., high octane fuels), and advanced powertrain work.

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SAE New Energy Vehicle Forum: China’s focus on NEVs may have profound impact on future of transportation

November 13, 2013

China has a number of critical economic and environmental imperatives driving its pursuit of vehicle electrification, said the roster of plenary speakers at the SAE 2013 New Energy Vehicle Forum held in Shanghai this week. These include the increasingly problematic pollution and haze in cities; China’s projected increased reliance on imported oil; the need for rationalized multimodal transportation systems in ever more congested and space-limited cities; the growing dominance of the China auto market; and the desire to have China become the leader in the next generation of automotive technology, vehicles and mobility systems.

The shift from fossil fuels to electricity—while held in common with other countries—will be based on the “specific situation” in China, making the best use of China’s own advantages and innovations, but also with international cooperation, said Dr. Zhixin Wu, Vice President of the China Automotive Technology and Research Center (CATARC). The details of that specific situation may result in an electric vehicle parc somewhat different than in Western countries, other speakers noted, and may indeed—given the obvious scale of the China market—herald a major transformation in transportation, including the type and role of personal vehicles, others suggested.

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Chrysler Group in 5-year, $18.2M partnership with McMaster University to develop advanced electric and hybrid powertrains; funding from Canadian Government

October 25, 2013

Chrysler Group LLC has entered a 5-year, $18.2-million partnership with McMaster University in Ontario, Canada, with funding support from the Canadian government, to develop next-generation, energy-efficient, high-performance electrified powertrains and powertrain components. For McMaster, the project partnership is one of three new partnerships with Chrysler, the federal government and other auto industry leaders worth a combined $24 million.

Chrysler Group will invest $9.25 million in cash and in-kind contributions, with an additional $8.93 million coming from the Natural Sciences and Engineering Research Council of Canada (NSERC), the lead agency within Automotive Partnership Canada (APC), an initiative that supports industry research at Canadian universities and government laboratories.

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ARPA-E announces $27M for transformational power electronics technologies

October 22, 2013

The US Energy Department’s Advanced Research Projects Agency-Energy (ARPA-E) has selected 14 projects for $27 million in funding to support the development of next-generation power conversion devices. The projects were selected under ARPA-E’s SWITCHES program (Strategies for Wide-Bandgap, Inexpensive Transistors for Controlling High-Efficiency Systems). (Earlier post.)

ARPA-E’s SWITCHES projects are creating innovative new wide-bandgap semiconductor materials, device architectures, and fabrication processes to enable increased energy density and switching frequencies, enhanced temperature control, and reduced power losses in a range of power electronics applications for electric motor drives and power switching devices for the grid.

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BRUSA picks up awards at eCarTec Munich 2013 for wireless charging and electric truck; synchronous motor shortlisted

October 17, 2013

The two components of BRUSA’s Inductive Charging System. Click to enlarge.

BRUSA won two of the eCarTec Awards presented at eCarTec Munich 2013 trade fair. BRUSA’s new ICS inductive charging system and the E-FORCE electric truck won in their particular categories, while BRUSA’s synchronous motor was shortlisted in the category of “Drive Technology, System Electrics, Testing Systems”.

BRUSA Inductive Charging System. BRUSA’s ICS was the winner in the category “Energy, Infrastructure, Connection Technology”. The new system only comprises a floor and vehicle plate—the required power electronics are integrated.

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DOE awards $45M to 38 advanced transportation technology projects; $3M from the Army

September 04, 2013

The US Department of Energy (DOE) will award more than $45 million to 38 new projects that accelerate the research and development of advanced vehicle technologies. Through the Advanced Vehicle Power Technology Alliance between the Energy Department and the Department of the Army, the Army is contributing an additional $3 million in co-funding to support projects focused on lightweighting and propulsion materials, batteries, fuels, and lubricants.

The 38 projects span five major areas: advanced lightweighting and propulsion materials; advanced batteries; power electronics; fuels and lubricants; and efficient heating, ventilation, and air conditioning systems.

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New high-temperature ceramic capacitor could reduce cooling needs in power electronics for hybrids and EVs

August 02, 2013

Scientists from the National Physical Laboratory (NPL) in the UK have developed a new lead-free, high-temperature ceramic capacitor that could improve the efficiency and reliability of electric and hybrid vehicles.

Hybrid and electric vehicles rely on high efficiency power conversion and management, with automotive power electronics representing an emerging £40-billion (US$61-billion) global market, NPL noted. The power electronics found in vehicles today require cooling because of limitations in the temperature rating of components such as capacitors, which are used to store electrical energy. This is a disadvantage as the extra cooling systems add weight to the vehicles, reducing efficiency and reliability.

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BRUSA electric drive components now available in 750-volt versions; targeted for commercial and very high performance

July 13, 2013

BRUSA 750V electric drive components. Click to enlarge.

BRUSA Elektronik AG is now offering its proven electric-drive components—including motor, controller, power electronics, battery pack and chargers—in 750-volt versions. The new 750-volt products are suited for use in commercial vehicles and applications demanding very high output performance.

Increasing the voltage reduces the current with the performance remaining the same. Lower current leads to a reduction of cable thicknesses and bending radii. This will directly result in weight and material savings—especially with commercial vehicles of a certain length such as trucks or buses, BRUSA says.

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ARPA-E to award up to $25M for work on WBG power semiconductor devices

June 13, 2013

The US Department of Energy’s Advanced Research Projects Agency - Energy (ARPA-E) has issued two new Funding Opportunity Announcements (DE-FOA-0000941, DE-FOA-0000942) for high-current wide bandgap (WBG) power semiconductor devices called “Strategies for Wide Bandgap, Inexpensive Transistors for Controlling High Efficiency Systems (SWITCHES).”

Both FOAs seek to fund innovative WBG semiconductor materials, device architectures, and device fabrication processes that promise to enable increased energy density, increased switching frequencies, enhanced temperature control, and reduce power losses in a range of power electronics applications, including high-power electric motor drives and automotive traction drive inverters.

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Obama Administration launches $200M competition for three new manufacturing innovation institutes; WBG power electronics, lightweight metals and digital manufacturing

May 09, 2013

The Obama Administration is launching competitions to create three new manufacturing innovation institutes with a Federal commitment of $200 million across five Federal agencies: Defense, Energy, Commerce, NASA, and the National Science Foundation. The effort is part of President Obama’s proposed $1-billion investment to create a network of 15 manufacturing innovation institutes across the country. (Earlier post.)

The Department of Energy will lead one of the new institutes on “Next Generation Power Electronics Manufacturing” for wide bandgap semiconductors such as silicon carbide (SiC) and gallium nitride (GaN) (DE-FOA-0000683). The Department of Defense will lead the other two, focused on “Lightweight and Modern Metals Manufacturing” and “Digital Manufacturing and Design Innovation”.

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Chalmers team developing new high-power integrated motor and battery charger; “rotating transformer”

April 30, 2013

Model of the integrated motor drive and battery charger. The image shows a plug-in hybrid electric vehicle, which also has a fuel tank and a combustion engine, but the technology system works equally well with a purely electric vehicle. Source: Chalmers. Click to enlarge.

Researchers at Chalmers University of Technology in Sweden have developed a new type of high-power integrated motor drive and battery charger for electric vehicles. Compared to today’s electric vehicle chargers, the new system could shorten the charging time from eight to two hours, and to reduce the cost by around $2,000, according to the developers.

Dr. Saeid Haghbin at Chalmers proposed the system which uses the components in the traction circuit—such as the electric motor and the inverter—in the charger circuit to reduce the size, weight and price of the on-board charger. In essence, the proposed system uses the motor as a grid-connected generator with extra terminals.

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Volvo upgrades C30 Electric with more powerful motor and 22 kW fast charger

April 23, 2013

The new 22 kW fast charger supports a full pack charge in 1.5 hours. Click to enlarge.

Beginning this summer, European leasing customers will drive and evaluate an upgraded demo fleet of 100 Volvo C30 battery electric cars that feature a new, more powerful motor from Siemens and a new 22 kW on-board flexible fast-charger from BRUSA.

The new Siemens motor for the generation II C30 has a peak power output of 89 kW (120 hp) and a torque of 250 N·m (184 N·m), enabling acceleration from 0-70 km/h (0-43 mph) in 5.9 seconds and 0-100 km/h (0 to 62 mph) in 10.7 seconds. The motor in the first generation C30 EV delivered 83 kW (111 hp) and 220 N·m (162 lb-ft).

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