Innovative e-machine and power electronics solutions for e-axle and e-corner vehicle powertrains

Abstract

The Horizon Europe EM-TECH and HighScape projects address innovative solutions for automotive electric powertrains, to achieve higher energy efficiency, reduced volume and mass, as well as reduced cost. The two projects are distinct yet complementary and synergic, where the former focuses on electric machines (e-Machines), while the latter on wide bandgap (WBG) based power electronics (PE). This paper outlines the main innovations of EM-TECH and HighScape, targeting a wide range of vehicle applications, including passenger cars and commercial vehicles. Specifically, EM-TECH deals with: i) modular designs of on-board axial flux machines (AFMs) for reducing the implementation costs of scalable centralised powertrains for electric axle (e-Axle) solutions; ii) in-wheel motors (IWMs) integrated with electric gearing, for expanding the high efficiency region of electric corner (e-Corner) powertrains; and iii) the use of permanent magnets deriving from recycling processes to improve sustainability. In parallel, HighScape targets the physical and functional integration of the PE of WBG based traction inverters, onboard chargers, DC/DC converters, and electric drives for auxiliaries and actuators.