Powertrain modularity

In this document the insulation system of the HEFT motor is discussed. In particular, the following
points will be explained: Evaluation of voltage stresses; Definition of target partial discharge inception voltages (PDIV); Reference insulation system; Characterization of slot molding resins; Assessment of phase-to-phase insulation system; Assessment of phase-to-ground insulation system; Assessment of turn-to-turn insulation system; Chemical compatibility. 

Climate change has created an increased need for innovation in various sectors, including the automotive industry. Many corporations are striving to fulfil this need by developing and producing electric cars. However, the production process remains inefficient and environmentally harmful. The EU-funded HEFT project will reverse this trend by introducing a revolutionary synchronous motor for electric cars, which will be recyclable, cost-efficient and require fewer materials while producing fewer emissions and creating novel European circular economies. 

HEFT Project proposes a set of innovation challenges on electric synchronous motor configuration based on SiC inverters (direct cooling of rotor and stator, advance insulation for high voltage, multibarrier rotor topology, wave windings) and advanced materials (advanced GBD magnets, epoxy for magnet fixation, composite for motor housing, insulation resin). These innovations will result in a high-efficient and low-cost solution that will be validated on 2 motor topologies.

In this document it details the work carried out in the HEFT project with regards to the objective of improving SiC-based drive control to reduce powertrain losses and improve EV range. The following issues will be covered:
1. Online variable switching frequency control strategy to optimize drive operation and reduce inverter and motor losses.
2. Optimal flux operation point to increase motor efficiency.
3. Improved powertrain thermal management strategy.
 

All these control aspects will be used in both A+B segment motor and C+D+E segment motor, as control strategy is the same for both motors that will be designed in HEFT project (only some parameters’ tunning need to be modified). Therefore, as use case, A+B segment motor has been selected, because this motor has already been designed. However, some preliminary results regarding C+D+E segment motor are also shown in this deliverable (this motor is still under development) to show that the proposed control strategy is valid for any IPMSM.