The power electronics inverter and DC/DC converter are two essential elements of any electric vehicle (EV); the first one drives the electric machine and the second one powers the low-voltage electrical system. Although the electric vehicle is the key to enabling a zero emission transportation system and provides a number of advantages, including superior driver comfort and control, there are a number of technical challenges which still impede their widespread adoption. The size, performance and cost of the inverters and converters are some of the main limiting factors which create cost and range anxiety in EV customers. Developing an innovative product overcoming the challenges is essential for both vehicle manufacturers and Tier-1/Tier-2 suppliers to increase the market shares of EVs by reinforcing their cost effectiveness, reliability and range.
This new technology, an integrated inverter-converter system (ICS) will reduced the volume of the EV/HEV powertrain, maximise the commonality while addressing concerns of reliability, fault protection and operation in the severe automotive environment with high efficiency. The performance will be increased through the use of emerging power semiconductor switches such as silicon carbide (SiC) devices, which have a reduction of switching losses at high frequencies. The high frequencies allow the use of smaller passive components. The size of the ICS is further reduced by functional integration of circuit components, integration of heat sinks, and compact fabrication methods. The cost-effectiveness of the system will encourage vehicle manufacturers to quickly adopt this technology and further increase the EV uptake in the society. Development of a compact power electronics system for harsh automotive environments is very challenging due to the increased thermal and mechanical stress on the components. The project will tackle the challenges with advanced thermal management, modelling tools and optimisation programs and will develop a superior inverter-converter system pushing the boundaries of the current state-of-the-art technologies.
HydroMAR-E will develop a mono-fuel Hydrogen version of the Recuperated Split Cycle Engine. This highly innovative thermal engine can be used in a range of heavy duty applications for land and sea. It offers very high efficiency (competitive with a PEM fuel cell), very low emissions (SULEV with aftertreatment), and ease of transition (existing ICE manufacture and installation requirements; moderate capital cost increase). Uniquely, and unlike a standard ICE, the RSCE has demonstrated ability to use Diesel, Methane and Hydrogen in the same core engine (and has potential for the same with Ammonia or Methanol) with the same high efficiency and low emissions, enabling a rapid transition as future fuels become more widely available.
HydroMAR-E will use a laboratory single cylinder engine, which has already demonstrated starting and running, to develop this spark-guided system to TRL4, then a multi-cylinder prototype to demonstrate TRL5 in readiness for future application demonstration in marine (and other) environments. Supporting work will develop an improved recuperator system, and review marinization, installation, vessel systems and regulatory aspects.
The project brings together the technology developer Dolphin N2 (Part of the Iveco Group, a global supplier of marine engines in the 100-600kW range), Brighton University (the UK APC's Thermal Propulsion Efficiency spoke), leading marine architects BMT, and recuperator technology developer Hiflux.
Within the EU, Heavy Duty Vehicles (HDVs) are responsible for 30% of on-road CO2 emissions. Hybrid & & electrification strategies, now being introduced in the light duty vehicle (LDV) sector are ineffective in HDVs due to prohibitive on-cost, high associated mass & compromised range & load carrying capacity. Without a sector-specific carbon reduction technology, the contribution & importance of HDV carbon emissions will inevitably rise as other sectors adopt effective low carbon propulsion solutions. To address the significant CO2 production within the sector, the UK Automotive Council roadmap calls for new thermodynamic cycles as a key medium-term objective. STEPCO2 represents a disruptive shift in combustion engine technology, & addresses this call through the use of split cycle technology with a novel step to significantly increase engine efficiency. Extensive feasibility studies supported by test results from previous projects, indicate the technology has potential to radically increase the efficiency of an engine in a HDV application. The project objective is to progress this game-changing concept from a research environment towards a working concept demonstrator & eventual application within HDVs, leading to drastic reduction in fuel usage & CO2 emission within the heavy duty transport sector.
Hiflux Ltd designs and manufactures revolutionary compact heat exchangers which recover up to 90% of waste heat in demanding high temperature and pressure applications. Hiflux technology has been proven in industrial field trials in markets such as small-scale combined heat and power, automotive, clean waste processing and hybrid energy systems. The heat exchanger technology features fine arrays of small pins laser welded between thin sheets arranged in a structure that combines strength to withstand pressure loads and flexibility to accommodate large thermal gradients. The resulting structure has a high level of material integrity but the automation is limited by the use of pulsed YAG laser technology. This project addresses how the process of manufacture, developed for small volumes, can be evolved so that Hiflux can demonstrate a clear path to economically viable high volume manufacture. Hiflux, together with project partners Imperial College and ECM Developments Ltd will investigate new ways of using continuous wave fibre lasers to achieve an optimal balance between throughput, initial capital expenditure, energy usage and total cost of ownership. The project will also examine the merits of adapting the manufacture techiques to production of high temperature micro-pin heat exchangers in combination with electro-chemical machining.
The split cycle engine represents a disruptive shift in engine technology that has the potential to radically increase the indicated thermal efficiency of a reciprocating internal combustion engine. The recent 'Cool-R' feasibility study, completed in December 2012 and co-funded by the TSB, suggested that the novel application of cryogen injection and isothermal compression, along with the recuperation of exhaust heat, offers the potential for a game-changing level of indicated thermal efficiency of over 60% for heavy duty diesel engine on-highway applications.
DC/DC converters are essential in electric and hybrid electric vehicles. These electronic devices step-up or step-down the battery voltage to a voltage level that suits the electric motor, the cabin supply or other essential loads. Current DC/DC converters are still expensive and heavy. A consortium of six UK manufacturers (Lotus, Turbo Power System, Industrial Capacitors Wrexham, International Transformers, Dynex, Hiflux) , one vehicle integrator (Hyperdrive) and Newcastle University are developing a new dc/dc converter design that reduces cost by up to 50% and weight by up to 40% compared to standard dc/dc converters. The main focus of their research is to reduce the inductor size which makes 50% of the overall weight and cost in a power dc/dc converter. A radical new converter design holds the key to achieve these targets. The 30 months programme is being supported by investment from the government-backed Technology Strategy Board (TSB).
Awaiting Public Project Summary
Awaiting Public Project Summary