National Projects
Modern drive system for passenger vehicles cooperating with on-board charger (iPower)
Title:
Modern drive system for passenger vehicles cooperating with on-board charger (iPower)
Acronym:
iPower
Name of the programme: Targeted Grants
Co-financing for Łukasiewicz-GIT from the funds of the Łukasiewicz Centre: PLN 1,020,000.00
Total project value: PLN 3,873,937.50
Start: 01.09.2022 / End: 31.12.2024
Consortium:
- Łukasiewicz Research Network – Institute of Electrical Engineering [Leader]
- Łukasiewicz Research Network – Upper Silesian Institute of Technology
- Łukasiewicz Research Network – Kraków Institute of Technology
- Łukasiewicz Research Network – Automotive Industry Institute
Executive Agency: Łukasiewicz Centre
Project Manager:
Robert Rossa, BEng, PhD
Tel.: 32 258 20 41 ext. 20
E-mail: robert.rossa@git.lukasiewicz.gov.pl
Objective:
The project provides for the design, construction and testing in laboratory conditions of a modern drive with an engine with a rated power of approx. 115 kW. The drive inverter of the developed system, equipped with the recuperation function, will be integrated with the drive motor. In addition, the inverter will work with the vehicle on-board charger. The on-board charger of the vehicle, cooperating with the drive inverter, will be adapted to power from a single- and three-phase network.
The developed new power electronic structures will be controlled by a new, designed and dedicated to this system master vehicle control unit (VCU).
The new designed and constructed on-board computer will also enable the control and integration of the drive system and charger with other vehicle modules, e.g. energy storage. The developed software will allow to expand the functionality of the controller with the possibility of controlling subsequent vehicle modules using Matlab Simulink.
Special features of the charger system include: a high-frequency power processing circuit ensuring galvanic separation from the power source and a two-way operating mode: V2G, V2H, V2V. The electronic structure of the converter will be designed in a compact form, integrated into the motor body. The power circuit structure of power electronic devices will be made on the basis of the latest SiC and GaN semiconductor technologies, in order to reduce the size of active components and minimise passive components. The housing will be designed specifically for the dimensions of the electronic structure of the converter and will provide the possibility of electrical, mechanical and hydraulic connections to the master control systems and the liquid cooling system.
It is foreseen that external passive components (chokes, capacitors) can be attached to the converter in order to ensure proper operation of all device functions. External components will be connected to the converter via links located on the housing.
The PMSM drive motor was selected due to its most favourable technical parameters. The developed motor will be adapted to supply DC voltage of approx. 600 V. This solution will be characterised by a high torque density and operation in the rpm range of 0 – 12,000.
The project aims to prepare a comprehensive technology enabling putting this type of drives on the market.
As part of the project, the technology of designing and manufacturing a complete housing of a modern drive system (motor-inverter-charger) for electric vehicles in an integrated form will also be developed. The technology will be based on guidelines and in cooperation with the constructors of these drive system components. The parts will allow to test the prototype system and use it in other construction solutions.
