Goals

MotorBrain sensor-, power and controller electronics:

• Design and Simulation of multiphase powertrain systems with special regards to efficiency, economical and safety aspects
• Development and assessment of novel smart and fault-tolerant motor topologies which exploit the possibilities of multi phase designs for higher efficiency, advanced integration possibilities and more safety
• Exploit new innovative magnetic materials - such as soft magnetic compounds (SMC) - to minimize the dependency on rare earth magnets
• Incorporation of fault-detection techniques and fault mitigation strategies, fault tolerant power electronic converter topologies and fail-safe control strategies
• Improving the performance and the integration abilities of fast switching inverters as well as passive components for highly integrated EV powertrains
• Study new advanced controlling techniques for distributed and central motor concepts

Investigate new process technologies to lower manufacturing cost and simplify recycling

Tasks

Development of multiple electrical machine concepts using MotorBrain sensor-, power- and controller electronics:

• Supply Chain 1 (Lead by CRF) : Smart integrated EV powertrain based on low power SMC e-motor for distributed propulsion with   integrated power electronics and passive components  (Figure 1)
• Supply Chain 2 (Lead by Siemens) : Smart integrated EV powertrain based on SM motor with moulded rotor and integrated sensors (Figure 2)
• Supply Chain 3 (Lead by Green Power) : Synchronous reluctance motor (Figure 3)

Within the Supply Chains of the Work Package different motor concepts and typologies will be investigated and realized. The main focus will be an enhanced efficiency, safety and a lower dependency on rare earth magnets - notwithstanding the exploitation of the possibilities the novel multicore controllers, sensors and inverters offer as well as the simulation of the whole powertrain.

The usage of SMC-components is of vital importance for the project since it application offers:

• More efficient electric motors due to lower losses at higher frequencies and higher pole pairs counts
• Advanced flux distributions and concentrations to substitute rare earth magnets (Figure 4)

Facilitates new design possibilities for a higher degree of integration and automatization during production