National projects
Project “State-of-the-art drive systems for passenger vehicles with on-board charger” – (PB_iPower) is supported by an earmarked grant from the President of the Lukasiewicz Center.
Total value of the project: 3 873 937,50 PLN
Funding: 3 835 937,50 PLN
The drive inverter of the developed system, with a recuperation function, will be integrated into the drive motor. In addition, the inverter will interact with the on-board charger of the vehicle. The vehicle’s on-board charger, working in conjunction with the drive inverter, will be suitable for single and three-phase mains power. The new power electronic structures developed will be controlled by a new drive master control unit (VCU) designed and dedicated to this system. The designed and manufactured new on-board computer will also enable the control and integration of the propulsion system and charger with other vehicle modules, e.g. energy storage. The programming developed will allow the controller’s functionality to be extended to control further vehicle modules using Matlab Simulink software. Special features of the charger system will be a high-frequency energy conversion circuit providing galvanic separation from the power source and a bidirectional mode of operation: 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 the power electronic devices will be based on the latest SiC and GaN semiconductor technologies, in order to reduce the size of the active elements and minimise the reactive elements. The enclosure will be specifically designed to the dimensions of the electronic structure of the converter and will provide electrical, mechanical and hydraulic connections to the master control systems and liquid cooling system. It is planned that external reactive elements (chokes, capacitors) can be connected to the converter for the correct operation of all device functions. External components will be connected to the converter via links on the housing. The PMSM-type drive motor was chosen for its most favourable technical parameters. The developed motor will be suitable for a DC voltage of approximately 600 V. The solution will feature high torque density and operate in the 0 – 12,000 rpm speed range. The project aims to prepare a comprehensive technology to offer this type of drive to the market. The project will also develop technology for the design and manufacture of a complete housing for a modern drive train (motor – inverter – charger) for electric vehicles of an integrated form. The technology will be developed based on guidelines and in collaboration with the designers of these power train components. The fabricated parts will allow the prototype system to be tested and used in various design solutions.
