Optimised DYnamics of high voltage powertrains: developing Sustainable Systems for Electric Vehicles

As the demand for fully EVs rises due to sustainability and decarbonization efforts, consumers’ concerns such as longer driving ranges and quicker charging times must be addressed. To this end, ODYSSEV is developing advanced automotive power converters and optimizing powertrain elements to utilize HV levels and novel electronic topologies. The project centers on a hybrid inverter concept that leverages the benefits of both RC-IGBTs and SiC MOSFETs under various load conditions, aiming for the best techno-economic performance. Innovations include optimizing the HV motor’s geometry and topology to avoid issues like partial discharge and current harmonics, and designing a reconfigurable battery pack. This battery pack can be charged at lower voltages (400-800V) and provide higher voltages (1200-1600V) during traction mode. The preliminary design targets a 1200V and 100 kW powertrain, with various scenarios to be analyzed for potential HVs. Additionally, ODYSSEV will innovate in areas such as the on-board charger, system packaging, and overall powertrain control. The project aims to demonstrate this HV powertrain integrated in a real vehicle in real driving tests, thereby providing evidence of reduced costs, losses, and weight for EV manufacturers. The ODYSSEV project involves a consortium of 14 partners from 8 countries, including research institutions, universities, and industrial stakeholders. This group will employ a Safe and SSbD, utilizing virtual environments with PHIL capabilities for cost-effective and efficient prototyping. The consortium has access to necessary facilities and networks for manufacturing, prototyping, and testing innovative automotive solutions. The expected impact includes a 30% reduction in energy losses and a 20% increase in driving range, with significant cost reductions (up to 20% for power electronic modules) and enhanced fast-charging capabilities (20-80% charge in 10 minutes with 350kW chargers).