Already 18 months have passed since the beginning of the project. Now that half the project is over, it is time to discuss everything which has been achieved so far by all the partners of the project.
Punch Powertrain has designed a very compact housing, including transmission, gearbox, GaN-based inverter (power, control and communication part) with associated fluidic cooling, and the electric motor. Punch Powertrain worked closely with ZG on the gearbox and the sizing of the housing, and with CEA regarding the GaN-inverter’s mechanical integration, which will power the electric motor, and which must be as modular as possible for the ease of assembly/disassembly. CEA is also working on the fault detection to guarantee the safety of the driver and in a second time, the equipment inside the car, but the work is still ongoing.
Brusa has designed a new generation multiphase (6 phases) high-speed motor with different technologies of rotors (permanent magnet and injected magnet), which will ultimately fit in the housing of Punch Powertrain and, as of today, will produce the first samples during the second half of 2019.
For the moment, the simulated maximum efficiency is over 97%:
As this new electric motor has 6 phases, TU/e is working on the motor control, and especially on the winding reconfiguration, to pass from a three phases system, to a six phases system; it will have some advantages at low/high speed to use one configuration or the other.
Chalmers is working on the regenerative braking, seeking efficient and safe brake blending control of the high-speed drive module. The integrated regenerative braking control maximizes energy recuperation with dynamic brake blending of the electric motor and brake system, maintains vehicle drivability and stability, and considers constraints and restrictions from the electric powertrain (battery, motor).
Figure 1. Driveshafts Torque vs Time
Switching from Driving to Braking: No Control and Control Comparison (ModulED Strategy); V = 50 km/h.
Next to this work, IKA studied and designed an algorithm to optimize the performance of the overall system for each individual block. The software is not fully finished, but each module can be optimized independently for the moment.
Siemens is now working in collaboration with the partners on the virtual integration of the different sub-systems within Simcenter Amesim. This will result in a model of the vehicle to assess the vehicle-level performances of the powertrain and to virtually expand the demonstration perimeter to non-physically testable operations in the project (driving cycles, weather conditions, etc.).
Since the beginning of the project, Efficient Innovation is helping the consortium on dissemination, communication and realized a full updated project exploitation plan hand in hand with all the partners.
Summer 2019 will be key in the project’s life as the first prototypes will be manufactured, and the life cycle analysis performed by Efficient Innovation to measure the environmental impact of the solution.