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A novel design of IGBT half-bridge power-modules for automotive applications was developed. In comparison to standard modules, advantages regarding electrical, thermal and mechanical interfaces could be achieved. In the present paper, investigations regarding the general design, the increase of lifetime and robustness and advantages from the applic...
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A variety of generator topologies are used in renewable energy applications. In recent years a new concept ‘permanent magnet induction generators’ has been developed. This generator type uses permanent magnets to provide magnetization flux in the machine, yet operates using induction machine principles, which leads to a near unity power factor and...
Citations
... The toolchain is illustrated at the example of an Inverter Building Block (IBB) comprising an IGBT half-bridge on a pin-fin base plate with DAB substrate, a DC-link capacitor, current sensor and a gate driver. Six IBBs are integrated in a 2x80 kW traction-drive [7] positioned in the sprung vehicle sector. The setup of the power electronic system is shown in Figure 2, which defines the Cartesian coordinate system (x, y, z) referenced in the following. ...
... Sectional view of the inverter[7] ...
The increasing integration of power electronic systems in highly stressed spaces to reduce interfaces, e.g. in the wheel hub or near the gearbox, leads to high demands for implemented electrical and mechanical components. To ensure field reliability new approaches predicting lifetime already in the development phase are necessary. The paper describes and applies a tool chain combining analytical, numerical and experimental methods to estimate the design life of an "Inverter Building Block" in a high-vibration environment. First, analytical models of bending beam and vibration theory are derived to pre-estimate its dynamic behavior. Second, a numerical model based on the finite element method is experimentally verified and power spectral density analysis applying standard loads are conducted. Third, a lifetime model referring to the linear damage accumulation thesis is implemented and compares the effects of different mounting scenarios in a passenger vehicle on the expected lifetime.
... The purpose of this study is therefore to show the fundamental efficiency limits resulting from the semiconductor technology. For this, a hard switching half bridge (Fig. 1), which is the basic element of most power converters like buck/boost converters or motor drive inverters, is used [3], [4]. The calculations are carried out on the example of a bidirectional buck/boost DC/DC converter. ...
... The drive unit shown in Fig. 3 is highly integrated and combines two permanent magnetic synchronous motors (PMSM), two sets of gears, the drive inverters, and the ECU. The drive inverters are based on inverter building blocks [2]. The mechanic and electronic components are connected to a common liquid coolant cirucit. ...
Power electronics technology demontrators for electric vehicle drivetrains are primarily designed to demonstrate the feasibility of novel technical approaches rather than for simple integration into vehicle communication networks. Documentation related to integration issues is often limited. Communication protocols are heterogeneous and tend to change frequently during the development process. Higher level software functions are often not fully implemented in the electronic control unit firmwares.
This paper presents the design and implementation of a vehicle control unit software, that is based on a rapid prototyping approach. The software design is flexible and modular enough to cope with the specific characteristics of technology demonstrators. Its features enable to test and recursively integrate these components into a vehicle. The software was employed to integrate a complete powertrain, exclusively composed of power electronics technology demonstrators, into a converted sports car.
... The twin-drive unit integrates two mechanically independent three-phase permanent magnet synchronous machines (PMSM), two sets of gears, two drive inverters sharing a common distributed dc-link capacitor, and the motor control unit (MCU) in a single, liquid cooled case. The drive inverters are constructed from six Inverter Building Blocks (IBB), each of which combines an IGBT commutator cell, a gate driver, a dc-link capacitor, and a current sensor on a single replaceable module [8], see Fig. 3. As motors and inverters are integrated in one common case, HV wiring is reduced to a short DC connection between drive unit and traction battery. ...
... Inverter Building Block[8]. ...
This paper presents the design and implementation of an experimental electric vehicle platform. The platform is intended for demonstrating and testing highly integrated power electronics drivetrain components in an actual vehicle, rather than just in laboratory and test bed environments. Most of these components were created in earlier research projects. The high voltage network topology is flexible enough to incorporate future developments and additional power electronics systems. A central vehicle control unit routes the signal flow between the vehicle’s electronic control units. It also controls the interaction of the drivetrain power electronics systems. Adding and exchanging devices is supported by the modular design of the vehicle control unit software. Special attention is given to the battery system, which was purposely designed for the vehicle platform.
The EU-funded FP7 project COSIVU [1] aims at a new system architecture for drive-trains of commercial vehicles. The project scope is the development of a smart, compact and durable single-wheel drive unit with integrated electric motor, compact transmission, full 1200V silicon carbide (SiC) inverter (switches and diodes) and an advanced and compact cooling solution. This paper focusses on the modular packaging concept of the integrated power stage, using 'Inverter Building Blocks', and the design of a double sided cooling of the power modules using a 3D printing technology.
