Ultra-Efficient Highly-Integrated 1200V Powertrains for Electric Vehicles Enabling Next-Gen Charging Speeds and Compatibility Across Charger Generations

Current mass-market electric vehicles (EVs) commonly operate at a voltage level of 400V.

There is however a clear trend to increase the voltage level towards 800V and beyond, as these higher voltages allow for faster charging and lower thermal loads in the system.

GEN1200 will focus on modular and scalable 1700V SiC-based power electronics solutions for highly-integrated 1200V powertrains, encompassing technologies for ultra-fast charging while ensuring compatibility with existing charging infrastructure, maximally exploiting the opportunities enabled by higher voltages.

The project activities will particularly result in: (i) innovative 1700V SiC power electronics systems with multiple use of components, e.g., the traction inverter will also embed the functionality of backwards compatibility with 400V or 800V DC charging and on-board AC charging; (ii) 1200V electric axle solutions with electrical, thermal and mechanical integration of the power electronics, electric machine, mechanical transmission, and a selection of auxiliaries; (iii) ultra-fast 350 kW charging of novel 10C battery modules with integrated electronics and a modular wireless battery management system for 1200V battery packs.

Innovations will be tailored to C-segment vehicles but extrapolation towards other segments will be considered.

All activities will be supported by the development of digital twins, as well as control solutions tailored to 1200V systems and for reducing power losses in partial load, and life cycle analysis.

Innovative testing methodologies, combining classical component and system characterisation, x-in-the-loop, and experimental vehicle assessment, will cover the wide range of relevant aspects, including efficiency, durability, electromagnetic compatibility and interference, as well as charging performance and sustainability.

GEN1200 will leverage the complementary competences and exploitation potential of 3 academic partners, 1 RTO, 2 SMEs and 2 large industrial players.