Inverters

Inverters for Mobile und Stationary Power Electronics Systems

The Inverters Research Group develops drive inverters for automotive, utility vehicle and aviation applications. Our focus is on the development of innovative, highly efficient, compact and reliable power electronics for drive converters in stationary and mobile applications. We carry out the complete research and development, prototype realization as well as testing and characterization of electric drives including motor control software on site at Fraunhofer IISB.

The mechatronic integration of inverter power electronics close to the electrical machine can reduce costs, installation space and EMC risks, but can also increase thermal and mechanical loads. At Fraunhofer IISB, we are therefore developing inverter system architectures with different levels of integration - from stand-alone housings to fully integrated inverter power electronics.

Customer-specific Prototypes

The development of efficient, highly integrated and reliable electric drive systems plays a key role in the electrification of the individual application areas.

Picture on the left: Axle drive unit for motor vehicles with integrated drive inverter

Development and prototype manufacturing of application-specific inverter power electronics

Electronics devices based on wide bandgap semiconductors (WBG), such as SiC and GaN transistors, allow inverter systems to achieve outstanding efficiencies, power densities and switching frequencies that significantly exceed the current state of the art. In order to realize the combination of highest output powers and currents with maximized switching speeds (> 20 kV/µs) in automotive and aerospace applications, a specifically tailored design of the commutation cell, the power module and the gate drive is necessary. At Fraunhofer IISB, we develop customized SiC and GaN inverters based on electrical and thermal simulations, supplemented by experimental test setups.  

  • Voltage range for typical automotive applications: 48 V to 850 V (and beyond)
  • Output power up to 1 MW
  • Focus on silicon carbide (SiC) and galium nitride (GaN) based inverter systems
  • Expertise in a variety of inverter topologies (Multilevel, Multiphase, etc.)
  • Application-oriented motor control software development for various types of electrical machines
  • In-house testing facilities with several motor test benches and a vehicle test bench

Areas of application: Traction, fuel cell air supply, electric turbochargers, highly integrated drives

3-Level Topologies

3-level inverter topologies offer significant potential for improving the efficiency of electric drive systems in various application areas.

Zur Pressemitteilung

© André Müller / Fraunhofer IISB

Design, development, assembly and characterization of 3-level inverter systems

Realization of technology demonstrators for various 3-level topologies:

  • NPC (Neutral Point Clamped) GaN-based 800 V converter
  • T-type silicon carbide (SiC) inverter
  • ANPC (Active Neutral Point Clamped) power module characterization

Inverters for High-speed Applications

Inverters for high-speed applications place special demands on switching frequency and motor control.

We develop SiC- or GaN-based inverters including motor control software for high-speed motors (e.g. compressors, fuel cell air compressors or electric turbochargers). These require the highest output frequencies on the inverter and therefore also high switching frequencies in order to avoid additional losses and torque carry-over in the machine. Wide bandgap semiconductors (WBG) are particularly suitable for use in these applications.

Typical requirements:

  • Nominal DC link voltage: 450 V and 850 V
  • Output power: 10 to 80 kW
  • 2- or 3-level topologies
  • Max. Switching frequency: 80-100 kHz
  • Sensorless motor control

Motor Control Software

The safe and efficient operation of electric drive systems requires the development of application-specific motor control software.

Fraunhofer IISB is cooperating with the Control Engineering Laboratory of the Faculty of Electrical Engineering, Precision Engineering and Information Technology (efi) at Technische Hochschule Nürnberg Georg Simon Ohm in the development and analysis of modular control algorithms for the following machine types:

  • Permanently excited synchronous machines (Permanent Magnet Synchronous Motors PMSM)
  • Asynchronous machines (Induction Motors, IM)
  • Externally excited synchronous machines (Electrically Excited Synchronous Motor, EESM)
  • Brushless DC machines (BLDC)
  • Mehrphasige und 3-Level Topologien

Based on our R&D activities, we offer the following solutions:

  • Conventional drive control methods (e.g. field-oriented control)
  • Adaptive control of drive systems (e.g. iterative learning control)
  • Sensorless control and high-frequency control algorithms, e.g. for high-speed drives (electric turbochargers, fuel cell air compressors, etc.)
  • Implementation and testing on self-developed control board hardware
  • Test of the developed drive controls on the in-house motor test bench

Studies on Inverter Systems

We offer an extensive range of measuring equipment and test benches as well as in-depth expertise with various simulation tools in order to carry out in-depth investigations into inverter-specific issues.

Simulative and experimental studies on drive converter-specific issues

Research projects provide the ideal framework for collaborations on new ideas and developments. Examples of typical topics are:

  • Packaging space and integration studies
  • Inverter topology or potential studies
  • Power module characterization
  • Simulative or experimental thermal studies (e.g. heat dissipation from power modules, DC link capacitors, etc.)

Smart Nodes for Automated Vehicle Power Supply Systems

Building set for smart power distribution nodes for on-board power supply systems of highly automated vehicles.

HiBord DC/DC with DLC storage

© Fraunhofer IISB
© Fraunhofer IISB
Hardware modules of the smart power distribution node building set
© Fraunhofer IISB
Block diagram of the HiBord DC/DC with DLC storage

Highly automated vehicles as of SAE level 3 lack the driver as a fallback during power failures.

In the research project HiBord, funded by the German Federal Ministry of Education and Research, new on-board power supply system topologies were investigated which can handle faults in the power supply system without full redundancy.

  • Energy flow control
  • Fault isolation
  • Network reconfiguration
  • Local reflexes and global decisions

 

Advantages:

  • Logic module with μC and FPGA for advanced monitoring algorithms and quick fault reactions
  • Scalability by using standardized interfaces
  • Modules equipped with sensors for current, voltage, temperature
  • Different communication options (CAN, Automotive Ethernet, …)
  • Scalable housing and cooling solution due to standardized module dimensions and connectors

 

Modules:

Many modules are available

  • Uni-directional and bi-directional switch modules (12V or 48V)
  • 48V/12V DC/DC converter module
  • Double layer capacitor module
  • Active and passive DLC pre-charging modules
  • Logic module with powerful FPGA and µC

… and more, depending on project requirements

 

Application Example

A combination of an on-board DC/DC converter and a DLC was realized with the building set and is a key component of the HiBord power supply system.
.The system combines a DC/DC converter with a transient power storage and thus can replace a 12V battery in fail-operational scenarios.

Electric Drive Testing Possibilities

Complete vehicle tests and characterizations can be carried out in a temperature controllable (-25°C/+50°C) all-wheel roller dynamometer.

© Kurt Fuchs / Fraunhofer IISB
Motor test bench

A variety of motor test benches up to 300 kW and 1000 VDC-power supply are available at Fraunhofer IISB and can be used for the characterization of electric motors and complete drive systems.

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