Alternative drive types

© Fraunhofer ISIT

 

Sustainable mobility, aiming to reduce emissions in transportation by at least 40 percent by 2030, primarily requires alternative drive types. In addition to natural gas (CNG, LNG, LPG) or hydrogen, electric drives, in particular, enable the environmentally friendly use of commercial vehicles. Although the market share of electric and hybrid vehicles has increased considerably, the limited range, high purchase costs, and regional gaps in the charging infrastructure require further technical innovations and new scientific approaches.

Efficient, compact, robust, reliable, highly integrated, raw material and cost-optimized

The list of requirements for electric drives is long, and, given the global race for the future electromobility markets, car manufacturers and suppliers are presented with significant challenges. It is not enough to optimize the batteries to enable electric vehicles to cover longer distances. Instead, the entire drivetrain must be improved to optimize driving dynamics and energy efficiency and improve the integration of power electronics components.

Fields of research:

  • Battery systems
  • Drive trains
  • Inverters
  • Drive inverters

Project examples

Reliable electrical connections for drive technology project with Fraunhofer EMFT

The research project is funded by the AiF Arbeitsgemeinschaft industrieller Forschungsvereinigungen "Otto von Guericke" e.V. (IGF application no.: N 09826/16, FVA no. 618 II "Raffungsmodelle II").
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Reliability of power electronics/modules in electric vehicles @ Fraunhofer ENAS

Selected examples and application scenarios: Canary structures based on SMD components with reduced solder widths for PHM I Highly integrated industrial motor control with self-learning capabilities and EMC- compliant design I "Design for reliability" in high-frequency electronics with alternative connection technologies for the intelligent mobility of the future I Optical in situ analysis of power components under active load cycling I Active and passive temperature cycling tests for automotive applications I "Design for reliability" in power electronics with new interconnect technologies for future smart mobility and smart energy solutions I Reliability evaluation and optimization of a smart drive unit I TRACE: Technology readiness for the use of consumer electronics in automotive applications I Profile optimization of multilayer PCBs in simulation and deformation measurement.
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Estimation of system reliability from component behavior including for electric and automated driving @ Fraunhofer ENAS.

A current research objective is to precisely determine the failure mechanisms at work, to predict the service life of the new systems on this basis and to be able to develop design proposals in order to meet the reliability requirements right from the first assembly.
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Research area of durability testing and modeling including for electromobility and automated driving @ Fraunhofer ENAS

By means of analytical testing and characterization (group 'Analytics and characterization') of real components in connection with the determination of life time, degradation processes can be clarified phenomenologically and analyzed precisely in quantitative terms. 

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PROPOWER project with Fraunhofer ENAS and Fraunhofer IISB

"Design for reliability" in power electronics with new interconnect technologies for future smart mobility and smart energy solutions.
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GaN4EmoBiL — GaN power semiconductors for electromobility and system integration by bidirectional charging @ Fraunhofer IAF

The goal of the GaN4EmoBiL consortium is to demonstrate an intelligent and cost-effective bidirectional charging system using new semiconductor, device and system technologies.
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Battery systems @ Fraunhofer IISB

In the Battery Systems group at Fraunhofer IISB we meet the growing demand by developing innovative solutions for rechargeable electrical energy storage systems, such as lithium-ion or redox flow batteries in mobile or stationary applications.

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Drive inverters & mechatronics @ Fraunhofer IISB

Projects: High Performance Integrated e-Drive, Integrated Drive Inverter for Wheel Hub Motors, Hybrid Traction Unit, COSIVU - Integrated 1200 V SiC-Inverter for Commercial Vehicles, Electric Drive Technology Platform, Inverter Building Block, Ultracompact Brake Chopper (German), ECPE Demonstrator Project (German), First Mechatronically Integrated Inverter Motor for a Vehicle Hybrid Drive (German), Re-Engineering Toyota HSD Power Electronics (German).
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Battery chargers @ Fraunhofer IISB

On-board battery chargers (AC/DC converters) in the range of 3.7 to 22 kW for plug-in and pure electric vehicles as well as DC chargers (DC/DC converters) in the range of 3 kW and more for ultra-fast high-performance applications. Projects: 500 W charging converters for ultra-capacitors.
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Inductive energy transfer @ Fraunhofer IISB

We develop and realize inductive power transmission systems. From FEM simulation, power electronics analysis / simulation and mechanical integration to the realization of complete prototypes. Examples include inductive connectors, inductive charging and inductive ball bearings.
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foxBMS® 2 - Certifiable open source battery management system @ Fraunhofer IISB

foxBMS is a free, open and flexible research and development environment for the design of Battery Management Systems (BMS). Above all, it is the first universal hardware and software platform providing a fully open source BMS development platform.

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Customized DC-DC converters for the automotive industry, aircraft and stationary applications @ Fraunhofer IISB

Fraunhofer IISB provides customer specific DC/DC converters for automotive, aircraft and stationary applications. Research starts on basic level switching behavior of classic silicon and modern wide band gap SiC and GaN devices. 

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SiC services, e.g. for (hybrid) electric vehicles @ Fraunhofer IISB

Drawing on 20 years of cooperation with partners from SiC industry and research, Fraunhofer IISB has been established as Germany‘s hotspot for silicon carbide power device manufacturing on a 150 mm SiC line. 

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Test center for electric vehicles @ Fraunhofer IISB

Vehicles with electric powertrains place completely new demands on measurement and testing technology. The new Fraunhofer IISB test center in Erlangen offers a unique infrastructure specifically tailored to these requirements, in which individual components of electric vehicles through to complete vehicles can be measured and optimized. The test center includes test benches for electric drives, energy storage, electrical-thermal reliability and electromagnetic compatibility.
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Aviation electronics @ Fraunhofer IISB

Making use of more than 20 years of experience in delivering complete prototype systems for automotive applications, IISB is able to provide technologies for the complete high voltage "backbone" of a more/all electric aircraft, ranging from non-/isolating DC/DC converters and AC/DC motor/grid inverters to complete battery systems and DC grid control technologies.

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Component characterization @ Fraunhofer IISB

The continuous reduction in product development times and the high cost pressure place special challenges for the developers of power electronic systems. In an early project stage, the optimal selection of the active or passive components saves time and costs. 

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SiC/GaN converters @ Fraunhofer IISB

From material to system and thus, completing the whole process chain of available SiC services, Fraunhofer IISB works on integration and optimization of SiC mechatronic systems for various fields of application.

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Electromagnetic compatibility - EMC laboratory @ Fraunhofer IISB

The EMC lab at the Fraunhofer IISB offers precise precompliance measurements during the development process of prototype systems and components of our industrial partners. 

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Project list of the Fraunhofer IISB in the field of vehicle electronics

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Ultra-thin components & circuits @ Fraunhofer IISB

Thin-film transistors and sensors for direct application in industry, automotive electronics, energy electronics and for use by end users.
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Reliability of power electronics/modules in electric vehicles @ Fraunhofer IAF

Monolithic integrated GaN power circuits with Fraunhofer IAF for mobility and other applications.
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Projekt GaNTraction - Fractal GaN modules for efficient and compact 48V drive inverters with Fraunhofer IAF

GaN technology enables the monolithic integration of entire circuit components, such as the half-bridge branches of a drive inverter, thus enabling even more compact chip solutions.

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Project IKEBA

Optimized software and hardware of management systems that monitor and control lithium-ion batteries with Fraunhofer IIS/EAS and Fraunhofer IZM. The project was funded by the German Federal Ministry of Education and Research (BMBF). The funding is part of the measure "Energy-efficient and safe electromobility" (STROM 2) in the program "ICT 2020 - Research for Innovation".
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Emission-free mobility @ Fraunhofer IMS

Fraunhofer IMS contributes to the research field of emission-free mobility. With its technologies, the institute supports the reduction of CO2 emissions and the development of emission-free mobility solutions. 

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Battery systems for special applications @ Fraunhofer ISIT

The business unit Power Electronics at Fraunhofer ISIT develops and manufactures innovative active and passive power semiconductor components based on silicon and gallium nitride, develops power electronic systems and integrates them with high-performance accumulators for special applications towards high-power storage systems.

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Fraunhofer ISIT develops energy-efficient and environmentally friendly manufacturing process for electrode foils in lithium-polymer batteries

Scientists at Fraunhofer ISIT are working on how production can be carried out more cost-effectively and in a more environmentally friendly manner, focusing on solvent-free production of the electrodes.

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Electronic energy systems @ Fraunhofer IISB

Active reliability with sensor integration, lifetime measurement, reliability-driven control, multi-chip power modules I Hybrid grids with medium-voltage DC applications, new components, grid-forming converters I Battery integration with charging stations, grid support, bidirectional power transmission.
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Project Ultimo

Ultra-compact power module of the highest reliability with Fraunhofer IISB, Fraunhofer ISIT and Fraunhofer IZM. Funded by VDI Technologiezentrum GmbH (BMBF).
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Miniaturized and highly efficient zero-dead-time drivers for Si, SiC and GaN applications @ Fraunhofer IZM

Project partner & funding body is ECPE European Center for Power Electronics e.V.
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Embedded SiC power module @ Fraunhofer IZM

Highest on-board function integration: Damped DC-Link, gate power supply, gate driver, 2 temperature sensors (one per switch), embedded current sensor, fast analogue short-circuit detection, signal insulation and digitalization.

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Ultra Low Inductive Multilayer Ceramic SIC Power Module @ Fraunhofer IZM

To make use of the superior properties of Wide Band Gap (WBG) semiconductors power modules are needed with optimized parasitic electromagnetic properties and high temperature capability, furthermore with the possibility for a high degree of integration.

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Project ForMikro-LeitBAN

Smaller, faster, more energy-efficient - high-performance components for the digital transformation with Fraunhofer IISB and Leibniz FBH.
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Project ForMikro-GoNext

Semiconductor material beta-gallium oxide offers the best conditions for next-generation power electronics with Lebniz FBH.
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