Highly Integrated SiC EV/HEV Traction Drive
Objective:
Technical Approach:
Accomplishments:
Next Steps:
Potential Impact:
Adam Morgan, Yang Xu, Dhrubo Rahman, Wensong Yu, Douglas C. Hopkins, Iqbal Husain
• Design and fabricate a 55kW SiC Inverter for an EV motor drive
• Meet/exceed the DoE’s 2020 power density target of 13.4 kW/L• Provide hands-on experience and training for next-gen
workforce
• Functional integration: impingement cooling of power modules and inductors• PCB-based busbar solution for distributed DC-link capacitors • Low-profile, compact inverter design currently achieves power density of 12.1kW/L
PMSM
#1 module #2 module #3 module #4 module
• Use of interleaved boosted inverter topology• Boost stage and inverter stage operating at
frequencies of 35kHz and 70kHz, respectively• Passive components (DC-link capacitors, boost
inductors) value and size reduction • Multi-physics simulation driven design• Custom design, using viable processes,
enables functional integration; thus high power density and lower weight
Total 200µF/900V
• Open-loop hardware test of SiC inverter on RL-load, up to 55kW continuous
• Address initial shortcomings of first design test results• Closed-loop hardware test of SiC inverter on dynamometer• Development of a marketable SiC-based inverter platform
battery current battery current
dc link currentdc link current
• Proliferation of clean, sustainable EV traction drives into commercial and industrial sectors to fight climate change
• Establish the U.S. as a technological leader in design and manufacturing of WBG semiconductors