Feature: Power
Hybrid vehicles to benefit from new type drive module
By Mersen electronic system design and development engineers
vehicle range in the shortest possible charging time. In the UK alone, demand for electric
A
vehicles (EVs) has started to soar as new car sales hit a 30-year low. A new study finds nearly 30% of Brits will choose electric mode of transport for their next vehicle. In 2022, EVs accounted for nearly a fiſth of all new car sales in the UK. However, EVs require further
development, especially to increase their daily use range, decrease their weight and battery sizes, shorten charging times and lower their overall cost. Therefore, at this point in time, hybrid electric vehicles are seen as a suitable stepping stone, combining the internal combustion engine (ICE) with electric power. A hybrid system is more efficient
s car buyers move away from classic-fuel cars and toward electric types, there are many companies and projects focusing on maximising
than any combustion engine because the ICE can be smaller.
European projects Many European projects focus on powering hybrid and electric vehicles. A project called InMOVE (Integrated Modular Electric Propulsion System For Parallel Hybrid Vehicles) successfully developed an electric propulsion system for hybrid vehicles. It was funded by the consortium partners and the EU, under the BRITE/EURAM 3 umbrella of the European Commission’s Fourth Framework programme. The project was led by Volkswagen, and involved the Fraunhofer Institute ISIT, Danfoss, Vishay, Reese+Thies Industrieelektronik, and the Kiel University of Applied Sciences. The goal was to develop a modular drive system for small- and mid-sized models of plug-in vehicles, based on modern gear concepts. Scaleability of the electric drive power and a variable drive architecture using
the same components were also key requirements. The partners developed a hybrid
drive module with a power output of 80kW, which delivers fuel consumption reduction of 25%. The drive motors are designed as compact, high-rpm electric machines with an integrated converter. Power train design was also simplified by using one clutch instead of two, for smaller size and cost savings. The InMOVE consortium also
involved the power solutions company Mersen, which provided a suitable DC link capacitor for the new engine, enabling alternating currents of 70A at 13.5kHz; see Figure 1. This high- current capability is made possible by an innovative cooling system and a flat design that improves heat dissipation.
Scaling and variability The modular concept for performance scaling and variability of possible drive technologies enables economies of scale
www.electronicsworld.co.uk February 2023 23
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