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.