Browse Topic: Power electronics

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Identifying and Mitigating Resonance Effects in HV Powernets: A Comprehensive Investigation into Current Ripple Effects in HV Power Nets2026-01-07427/1/2026
HV Power nets of electric vehicles consist of various HV components such as batteries, inverters, auxiliaries and cables. During in-vehicle testing, multiple failures of an auxiliary inverter were observed, caused by resonance issues within the component filter. Initial investigations revealed that these resonances, absent during manufacturer testbench evaluations, were influenced by the vehicle power net and its impedance characteristics. To better understand the underlying causes and identify preventative measures, extensive simulations were performed. The results demonstrate a diminishing influence of the power net capacitance when significantly larger than the component capacitance. Also, they highlight the critical impact of cable inductance on the component resonance frequency when comparable to the component’s inductance. A simplified electrical equivalent circuit was used to derive an equation predicting the resonance frequency as a function of the component’s capacitance/inductance and the cable length to the main power net capacitances. Based on these findings, recommendations for component filter design and testing protocols were proposed to mitigate similar failures in future applications.
Schmiel, Fabian, Aurand, Tobias, Koehnlechner, Benjamin, Zimmer, Markus
Passive Thermal Management of Battery Disconnect Units for Fast-Charging Electric Vehicles: A Comparative Study of Phase Change Material Heat Transfer Configurations2026-01-07597/1/2026
The widespread adoption of electric vehicles is currently hindered by long charging durations and limited infrastructure. While fast-charging technologies address these issues, they impose significant thermal loads on high-voltage components. Within this architecture, the Battery Disconnect Unit plays a critical role as it monitors and controls the connection between the battery, powertrain, and charging system. However, the high currents required for fast-charging often drive these units' temperatures beyond safe operating limits, necessitating advanced thermal solutions that do not require extensive redesigns of the vehicle's electrical layout. To address this challenge, this study proposes a passive thermal management solution using Phase Change Material heat transfer devices to enhance the thermal robustness of the component. The methodology employs a dual approach involving initial experimental testing to pinpoint specific thermal hotspots under high-power conditions, followed by detailed numerical simulations using GT-Power software to predict system behavior. Furthermore, the paper provides a comparative analysis of various configurations, assessing their impact on temperature reduction, response time, and thermal uniformity. The results demonstrate that appropriately designed passive solutions significantly improve thermal performance, effectively enabling higher charging power capabilities while minimizing system complexity and integration effort. This innovation provides a scalable and efficient path for improving overall vehicle performance and safety during rapid energy transfer events.
Salameh, Georges, Goumy, Guillaume, Frecinaux, Anthony, Ratajczack, Christelle, Palluel, Marlène, Noiseau, Pascal, Lardeux, Sébastien
Integrated DC Boost Charger in Post-800V Architecture with Open-End Winding Machine – Magnetic-Domain Modelling and Torque Analysis2026-01-07397/1/2026
Next-generation powertrain architectures proposed within EU Horizon projects adopt operating voltages above 800 V, providing improvements in efficiency as well as reductions in copper usage and system weight. However, post-800 V vehicles must remain backward compatible with existing 400 V and 800 V charging infrastructure, which requires the installation of an additional onboard DC boost charging unit on the vehicle. This paper proposes an integrated DC boost charging solution that reutilizes the open-end winding electric machine and the traction inverter of the electric powertrain, enabling backward compatibility while further reducing system cost and weight. In charging mode, the electric machine is repurposed as a passive inductive component, imposing a strict requirement of stationary operation with zero torque generation, which fundamentally differs from the driving mode characterized by rotor rotation and electromagnetic torque production. Consequently, conventional electric machine modeling approaches based on the rotor-oriented reference frame are not applicable to charging operation due to the unsymmetrical and unbalanced three-phase currents in the machine windings. To evaluate the machine behavior and develop charging control strategy, this paper introduces a magnetic-domain model based on physical model using phase self- and mutual-inductance parameters, from which the electromagnetic torque is directly derived based on the interaction between magnetic flux and phase currents. The simulations compare the charging current ripple and electromagnetic torque generation of a stationary open-end winding machine under two charging configurations: open-winding charging and neutral-point charging. The results show that the open-winding charging configuration exhibits lower current ripple than the neutral-point charging configuration due to higher inductance utilization. However, a non-zero charging torque is generated in the open-winding charging configuration and is strongly dependent on rotor position. The specific rotor positions corresponding to zero torque are identified and used to optimize the charging process.
Wang, Haoran, Kallur-Krishnamoorthy, Rajesh, Neuhaus, Christoph, Andert, Jakob
Design and Prototyping of a Winding Reconfiguration System for Electric Traction Applications2026-01-07307/1/2026
Battery electric vehicles (BEVs) place high demands on electric drives across a wide operating range: high efficiency in customer-related driving scenarios and maximum performance in dynamic driving modes. A promising solution to this challenge is the dynamic reconfiguration of the electric machine winding configuration between series and parallel mode, enabling optimal electromagnetic properties of the drive for different operating points. This paper presents the design and prototyping of an electronic winding reconfiguration system for high-performance traction applications. The hardware prototype has been designed and built, but has not yet been tested, which is why the results are based on simulations. Unlike mechanical winding reconfiguration concepts, which have long transition times and cannot switch under load, the proposed system enables fast and safe load transitions between the winding configurations. The study describes the topology and hardware of the switching unit, including the integration of power semiconductors, the required connection assemblies, cooling concept and the control of the power electronics. A novel control strategy is presented that ensures continuous current paths during switching, prevents overvoltage in the windings and minimises torque interruptions. To this end, the active short-circuit operation of the electric drive is taken into account. Simulations show that the system achieves efficiency gains of up to two percentage points in the partial load range while maintaining its full performance. The additional losses caused by the switching unit remain low in the partial load range, ensuring a net efficiency gain. The proposed concept offers a practical approach to extending the range of BEV drives by dynamically reconfiguring the windings of the electric machine, thereby improving partial load efficiency without compromising performance.
Oestreicher, Raphael, Schneider, Jörg, von Ohlen, David, Fuchs, Patrick, Kulzer, André Casal
Stochastic Gradient Pulse Adaptation for Grid Friendly DC Fast Charging of Battery Electric Vehicles2026-01-07347/1/2026
This paper presents Stochastic Gradient Pulse Adaptation (SGPA), a real-time adaptive pulse-charging system for rechargeable electrochemical batteries that dynamically adjusts charging aggressiveness based on the battery's internal response, as opposed to predetermined CC–CV or fixed pulse profiles. SGPA is different from traditional charging methods that use static current de-rating and conservative voltage limits. Instead, SGPA uses gradient-based feedback from terminal voltage behaviour, temperature changes, internal resistance changes, and state of charge to continuously adapt pulse amplitude and duty cycle. This algorithm boosts the charging intensity when the electrochemical circumstances are good. It lowers the pulses slowly when signs of thermal or impedance-related stress show up. Simulation-based proof-of-concept experiments on a heavy-duty multi-battery system show that charging time is less than with multi-CCCV charging, while still keeping the current distribution across packs balanced. The suggested SGPA method adds an adaptive charging algorithm that is easy to understand and ready to use. It makes fast charging more efficient without lowering voltage and thermal safety limits.
Prakashkumar, Balagopal, Mannar, Vignesh
Improving Reliability of an Automotive Power Electronic Unit Using Locally Resonant Metamaterials2026-01-07016/20/2026
The transition from internal combustion to electric vehicles requires assessing new challenges posed by novel components, materials, and manufacturing processes. These include assessing new types of excitations and damages from a reliability perspective. This paper investigates a solution to enhance Printed Circuit Board (PCB) reliability within automotive Power Electronic Units (PEUs). Controlling vibration levels is crucial to prevent component breakage and PEU failure. The proposed approach exploits Locally Resonant Metamaterials (LRMs) to reduce PCB vibrational loads. LRMs provide excellent Noise, Vibration, and Harshness (NVH) performance within specific frequency ranges while being lightweight and providing high design freedom. Since direct integration into the PCB is unfeasible, the aluminum spider frame securing the PCB is treated instead. Previous simulations demonstrated significant vibrational load reduction. In this study, the LRM solution is fabricated, and experimental validation is performed using a shaker test mimicking operating conditions. Multiple configurations are explored: two concepts tuned to individual PEU resonance frequencies, and a hybrid configuration targeting both peaks simultaneously. Finally, relative damage is calculated using experimental data, comparing configurations with and without the LRM solution, demonstrating how this method can evaluate the LRM solution's performance in such applications.
Tincani, Sara, Claeys, Claus, Deckers, Elke, Pandiya, Nimish, Dindorf, Christian
Influence of Common-Mode Voltage Reduction Techniques on High-Frequency Sideband Vibrations in IPMSM Drives for EVs2026-01-06956/20/2026
Space vector pulse width modulation (SVPWM) induces common-mode voltage (CMV) in three-phase voltage-source inverters, producing steep voltage edges that can lead to high leakage currents. In electric drive applications, these currents accelerate motor bearing degradation and may cause winding insulation failure. Active-zero-state PWM (AZSPWM) and near-state PWM (NSPWM) have been proposed as alternative modulation strategies to mitigate CMV and reduce drive degradation. This paper investigates the noise, vibration, and harshness performance of AZSPWM and NSPWM in comparison with conventional SVPWM. The proposed CMV reduction schemes are evaluated in terms of both CMV mitigation and their impact on high-frequency sideband vibration harmonics. Experimental results demonstrate that the CMV reduction strategies are highly effective in lowering CMV levels relative to SVPWM; however, this benefit is accompanied by an increase in vibration levels, which may adversely affect the mechanical integrity of the drive system despite the reduction in bearing leakage currents.
Khamis, Mahmoud Aly, Tatar, Andrei Alexandru, Repecho, Victor, Doria-Cerezo, Arnau
Passenger Car Powertrain for Voltages above 800V2026-37-00206/9/2026
The EU funded innovation project High-Voltage fast-charging Efficient electric vehicle Powertrains (HiVEP) develops innovative technologies for mass-market electric vehicles (EVs) by advancing architectures operating above 800 V. These architectures integrate silicon carbide (SiC)-based power electronics, rare-earth-free electric machines with active winding reconfiguration, high C-rate batteries, and optimized thermal management systems. HiVEP aims to enable fast charging in less than ten minutes, reduce energy consumption by at least 25%, extend the driving range by 20%, and cut system costs by up to 20% in volume production. This article deals in detail with the project objectives, the methodological approach, and the expected key innovations, as well as the technical, environmental, and social impacts. The discussion situates HiVEP within the European research and innovation landscape, emphasizing its role in accelerating adoption of sustainable mobility solutions.
Schernus, Christof, Nada, Shady, Neuhaus, Christoph, Ewald, Jens, Swierc, Daniel, Kallur-Krishnamoorthy, Rajesh, Vasiliadis, Harilaos
Rapid Modeling of Transient Thermal Systems through Ensemble Parameter Estimation Applied to the Lumped Parameter Linear Superposition Method2026-01-50345/19/2026
Efficient thermal modeling is essential for the design and reliability of power electronics systems, particularly under fast transient operating conditions. Building upon prior formulations of the Lumped Parameter Linear Superposition (LPLSP) method, this work introduces an ensemble parameter estimation framework that enables reduced-order thermal model generation from a single transient dataset. Unlike the earlier implementation that relied on multiple parametric simulations to excite each heat source independently, the proposed approach simultaneously identifies all model coefficients using fully transient excitations. Two estimation strategies namely two-stage decomposition and rank reduction are developed to further reduce computational cost and improve scalability for larger systems. The proposed strategies yield models with temperature-prediction errors within 5% of CFD simulations while reducing model development times from O(103 s) to O(100 s)–O(101 s). Once constructed, the model evaluates new transient operating conditions in O(100 s), enabling rapid thermal analysis and enabling automated generation of reduced-order models for both simulated and physical systems. These advancements significantly accelerate early stage design iterations and mission-profile evaluations for thermal management of electronic systems.
Padmanabhan, Neelakantan
Accelerating Electrification through Modular Propulsion: GM’S Strategy for BEV and BET Platforms2026-01-04104/7/2026
General Motors (GM) continues to advance its electrification strategy through the development of scalable Battery Electric Vehicle (BEV) and Battery Electric Truck (BET) platforms. This paper highlights GM’s latest BEV and BET products that leverage shared Drive Unit (DU), Rechargeable Energy Storage System (RESS), and integrated power electronic (IPE) components across multiple vehicle programs. By adopting a modular and commonized propulsion architecture, GM achieves significant benefits in manufacturing efficiency, cost optimization, speed to market, and product flexibility. The shared DU, RESS, and IPE components are engineered to meet diverse performance requirements while maintaining high standards of energy efficiency, thermal management, and durability. This approach enables rapid deployment of electrified solutions across various segments, from passenger vehicles to full-size trucks, without compromising on capability or customer experience. The paper outlines the technical rationale behind component commonization, including design considerations and integration challenges. Through this shared architecture, GM demonstrates how intelligent component reuse can accelerate innovation, reduce complexity, and support the transition to a zero-emissions future. The findings presented offer valuable insights into the role of scalable propulsion systems in shaping the next generation of electric mobility.
Liu, Jinming, Sevel, Kris, Anwar, Mohammad, Oury, Andrew, Welchko, Brian, Gagas, Brent
Physical Test Validated Multi-Level Power Electronics for Next-Generation Electrified Vehicles Charging & Efficiency Improvement2026-01-04354/7/2026
Improving the energy efficiency of electrified vehicles remains a central objective in modern electric powertrains. Multi-level converters (MLCs) are widely recognised for lowering conversion losses relative to two-level inverters and improving total harmonic distortion (THD) in the sinusoidal supply to motors with a consequent reduction in motor losses. Despite this, sustained production-oriented validation at the integrated system level remains limited. This work introduces a multi-level converter architecture of the Battery Integrated Modular Multi-Level Converter (BIMMC) topology using Cascaded H-Bridge (CHB) architecture. It offers improvements in all key metrics of performance, cost, package size, mass and robustness compared to the current state-of-the-art two-level inverter system with distributed functions for charging available in the market today. The overall solution is highly functionally integrated. It supports four major functions required in electric vehicles without the need for additional hardware. Firstly, supply to and control of a three-phase electric motor without the need for a separate, standalone inverter. Secondly, all usual battery management system (BMS) functionality including energy and State of Charge (SOC) management to module level enabling usable energy and robustness improvements. Thirdly, the ability to charge from both alternating current (AC) (single phase and three-phase) and direct current (DC) sources without the need for separate on-board charger (OBC) hardware whilst also enabling an innovative pulse charging approach which benefits both charging time and battery ageing compared to conventional DC charging. Finally, the ability to deliver a controlled DC supply to non-traction loads on the vehicle with high efficiency and redundancy. The BIMMC topology proposed has been designed, built at prototype level and tested in order to collect performance data to empirically validate empirical study of the performance and functional benefits of the approach for traction motor drive, battery stored energy management and charging. Measured results demonstrate that improved inverter waveform quality correlates with lower motor harmonic losses and measurable drive-cycle efficiency gains, consistent with prior MLC assessments. Battery SOC depletion can be managed actively within the complete battery yielding increased usable energy and further driving range gains. Pulse charging shortens charge time whilst maintaining battery health metrics within acceptable limits, aligning with experimental evidence on pulse-based fast charging. The topology has also demonstrated the ability to pulse charge cells in a complete battery pack whilst consuming incoming DC supply current from a standard commercially available DC charger (Electric Vehicle Supply Equipment - EVSE). This potential to offer the benefits associated with pulse charging without requiring change to existing deployed charging infrastructure. Overall, proposed CHB-BIMMC architecture offers a practical blueprint for next-generation electric vehicles (EVs), and is compatible with ongoing integration trends that converge traction, charging and battery management functions within a unified power electronics and control platform.
Bao, Ran, Kalaiselvan, Prashanth, Rener, Kristof, Hallam, Philip, Shi PhD, Kai, Yue, William, Ma, He, Grimshaw, Andrew, Patel, Simon
Characterization of a Low-Cost Insulator Substrate for Traction Power Modules2026-01-01194/7/2026
Demand for cost-effective automotive traction inverters requires improved power module packaging. This paper presents a packaging method using an epoxy composite insulator applied directly to the cold plate surface, replacing Direct Bonded Copper (DBC) and Active Metal Brazed (AMB) substrates. This integration removes the substrate-to-cold plate solder interface and eliminates two material layers from the thermal path. The epoxy composite demonstrates a dielectric strength greater than 60 kV/mm. Thermal resistance (junction-to-coolant) measured approximately 0.17 K∙cm2/W. Electrical characterization showed a relative permittivity of 3.9, which is lower than standard ceramics and results in reduced parasitic capacitance. Initial thermal cycling tests indicated no significant degradation in thermal or electrical performance. These results suggest the epoxy composite insulator could be a promising alternative for traction power modules.
Chen, Yu, Mena-Garcia, Javier, Chen, Hao, Xiao, Kewei, Gupta, Man Prakash, Degner, Michael
From Propane to Pi: Affordable AI-Driven Solutions for Sustainable Bus Heating2026-01-01644/7/2026
This paper proposes an intelligent, artificial intelligence (AI) enabled seat heating system for school buses that saves energy by only activating heating elements when a passenger is identified. A custom-trained YOLOv8 deep learning model identifies passengers in real time and opens/closes real-time control of the individual electric seat heaters via a Raspberry Pi 5. The detector achieves around 10 frames-per-second (FPS) of inference on the Raspberry Pi 5 and 80–90 FPS on a laptop with over 92% detection confidence across various illumination conditions. Energy modeling shows the anticipated demand for a 10-kW propane-based heater is approximately 75% lower by implementing a 2.52 kW electric seat-heating system. In a typical operation schedule of 540 hours a year, this results in 4,000–5,000 kWh of annual savings, $465–$579 of annual cost savings and mitigates 0.9–1.3 t CO₂ per bus, annually. When implemented at the fleet level, the energy and cost saving will be in proportion. This approach offers a cost-effective, modular, and safe electrified public transportation solution that integrates comfort optimization with environmental accountability.
Chikkala, Daney Bhargav, Zadeh, Mehrdad, Tan, Teik-Khoon, Ponnam, Jitin, Batte, Jai Rathan
Methods of Highly Repeatable Lubricant Testing for Electrified Vehicles: Universal Motor Control and Statistical Test-Variation Analysis2026-01-04214/7/2026
This paper describes a systematic approach to evaluate lubricants for hybrid and electric vehicles (xEVs) that can detect impacts on efficiency as low as 0.1 percentage points. Two testing methods were developed to evaluate lubricants’ efficiency effects: (1) on a complete vehicle (using the manufacturer’s hardware and motor control) and (2) on a standalone drive unit (using custom power electronics and control). A Monte Carlo simulation was used to analyze the resulting data to determine the detection limits of the vehicle test method. To evaluate the effectiveness of the test stands and the data-analysis method, a Tesla Model 3 electric drive unit and a Chevrolet Bolt battery electric vehicle (BEV) were characterized for system efficiency. For the Bolt mounted on a hub driven chassis dynamometer, this method is capable of detecting a change in the drive unit’s electromechanical efficiency between baseline and candidate fluids of <0.4 percentage point (pp) with 95% confidence at most of the operating points analyzed. This method can be applied to high-precision testing applications, such as lubricants or additives, cooling systems, gear trains, dynamic seals, bearings, or electric motor designs.
Luo, Yilun, Gross, Michael, Kostan, Travis
Comparative Analysis of Flux Linkage Characterization Methods for Automotive Permanent Magnet Traction Motors: A Critical Review and Performance Evaluation Framework2026-01-04414/7/2026
Accurate flux linkage characterization is essential for the design, control, performance and efficiency optimization of permanent magnet (PM) traction motors in automotive applications. Precise knowledge of flux linkage across varying load, speed, and temperature conditions directly impacts torque production, field-weakening capability, overall drive system efficiency and torque security. This paper presents a critical review and classification of flux-linkage characterization methods, encompassing offline laboratory mapping, standstill signal injection, self-commissioning inverter-only routines, and online real-time estimation. Each method exhibits distinct trade-offs in terms of accuracy, robustness to inverter nonlinearities, temperature adaptability, cost, and scalability for production and in-vehicle use. With the increasing complexity of automotive traction systems, understanding these trade-offs is crucial for optimal motor design and control. To enable systematic comparison, a performance evaluation framework is introduced based on key performance indicators (KPIs), including accuracy (below base speed, field weakening, and regeneration conditions), robustness to stator resistance variations and inverter nonlinearity, thermal adaptability, test complexity, time efficiency, cost, and applicability across the motor development lifecycle. These KPIs were selected based on their direct impact on motor performance, manufacturability, and suitability for various stages of automotive traction motor development, ensuring that analytical, dyno testing, and in-vehicle considerations are addressed.
Khan, Ahmad Arshan, Haddad, Reemon, Kim, Jay, Hermann, Justin, Mohamadian, Mustafa
Simulation of Conjugate Heat Transfer using the Lattice Boltzmann Method2026-01-01354/7/2026
Flow simulation with conjugate heat transfer, which involves fluid flow, conduction, and radiation within solid components, is a vital capability that enables engineers to design and assess cooling systems for heat-producing parts such as brakes, powertrains, batteries, and power electronics in both gasoline and electric vehicles. In this study, we employ PowerFLOW®, which features a thermal solver capable of simultaneously modeling both fluid and solid domains within a unified framework. The fluid flow is simulated using the Lattice Boltzmann Method (LBM) with VLES turbulence modeling based on the RNG k–ε approach. The solid domain is solved using a finite volume method with second-order accuracy for thermal conduction, combined with surface-to-surface radiation modeling for thermal exchange between surfaces. This integrated approach streamlines the simulation workflow while enabling accurate representation of both conduction and radiation phenomena. We assess the accuracy of the conjugate heat transfer (CHT) simulation methodology for both forced and natural convection benchmark cases. For the forced convection case, channel flow with heated mounted cubes was analyzed, while for the natural convection case, a simplified engine bay under soak conditions was simulated. In both configurations, the simulation results showed good correlation with experimental data, demonstrating the reliability of the CHT approach.
Mukutmoni, Devadatta, Shock, Richard, Li, Han, Wanderer, John, Gopalaswamy, Nath, Miao, Ling
ZSI Impedance Source Inverter Integrated XFC (Extreme Fast Charging) for Electric Vehicle2026-01-04384/7/2026
This paper explores the application of an Improved Enhanced-Boost Quasi-Z-Source Inverter in AC-connected extreme fast charging (XFC) stations for electric vehicles (EVs), aiming to reduce conversion stages and enhance system efficiency. AC-connected XFCs offer superior reliability compared to DC-connected systems due to better fault tolerance and reduced sensitivity to power fluctuations but traditionally suffer from increased complexity and reduced efficiency due to multiple conversion stages. The proposed inverter addresses this by combining DC-DC and DC-AC conversion into a single stage, simplifying the system, decreasing losses, and improving efficiency. Furthermore, this research investigates the use of Spiking Neural Networks (SNNs) for generating the precise pulse width modulation (PWM) signals required for the Quasi-Z-Source Inverter. SNNs offer potential advantages in terms of dynamic response and adaptability compared to traditional PWM techniques, allowing for optimized inverter control under varying load conditions. By operating at a higher modulation index, the inverter reduces switch stress, making it suitable for high-power applications. Analytical results and simulations demonstrate the inverter's potential, enhanced by SNN-based pulse generation, in advancing next-generation fast charging solutions by simplifying infrastructure and improving charging efficiency, positioning it as a promising technology for the future of electric vehicle charging.
Saliesh, Dileep, Sanaboyina, Prudhvi, Chhagar, Rohnitsingh, Satyanarayan, Swapna
New Inverter Switching Control Method to Enhance Sound Quality for Electric Vehicles2026-01-04374/7/2026
Conventional inverter control uses a fixed switching frequency, which leads to high-pitched switching noise in electric vehicles (EVs) that does not vary with vehicle speed. Although EVs are much quieter than traditional internal combustion engine (ICE) vehicles, some EV owners complain about the lack of dynamic driving sound feedback. A new patented technology has been developed to enhance EV sound quality by dynamically controlling the inverter switching frequencies. This technology generates dynamic propulsion sound with new "switching order" features at multiple harmonics, with the pitch proportional to vehicle speed. A constant pulse ratio between the switching frequency and the electric motor RPM is implemented to control the switching order. This reduces switching losses during low-speed operation and provides boosted acoustic feedback to the driver during acceleration, which enhances driving experience during sports driving. Furthermore, a special "EV shifting" sound that mimics the sound of gear shifting is generated by controlling different pulse ratios at each shifting RPM zone. High switching orders are dropped between neighboring zones to boost lower frequencies for an enhanced dynamic driving experience. These new switching sound features have been validated through electric drive unit and electric vehicle tests. Jury tests confirm the new EV sound with switching orders is authentically generated from electric propulsion system and can be tuned by controlling the switching pulse ratio. This technology has been successfully implemented in the "Watts-to-Freedom" drive mode of the Hummer EV, providing enhanced EV sound feedback, and improving the driver's experience during high-acceleration events.
He, Song, Gagas, Brent, Welchko, Brian, Ball, Kerrie, Gong, Cheng
Propulsion System Design Considerations for HEV Versus EV Applications2026-01-06414/7/2026
The design and development of EVs and HEVs has become a growing issue recently due to concerns about pollution and dependence on non-renewable fossil fuels. Accordingly, General Motors (GM) has an evolving vehicle electrification plan over the past several decades and into the future to deliver low-cost and efficient EVs and HEVs. Propulsion system requirements for the applications of EV and HEVs are quite different and therefore, the design principles and directions are also distinct between these cases. From micro-hybrid and full plug-in hybrid applications to full EV applications, design requirements, strategies and outcomes can widely vary. Continuous and peak duty are substantially different depending on the application of the vehicle. Motor operational duty is significantly higher for EV compared to the electric motor of a hybrid electric vehicle. Motor torque, power and efficiency requirements are also higher for EV motors, which greatly influences the choice of motor type and its thermal and electromagnetic design. Issues like NVH and thermal can be less significant in designing motors for HEV because of engine masking and lower duty cycle of operation. Motor design requirements, optimization process and results for two different motors intended to be used in EV versus HEV applications are discussed in this paper. Moreover, traction inverter requirements differ significantly across electric vehicles and various hybrid architectures. Each configuration presents distinct challenges—ranging from packaging and thermal management to vibration and electrical constraints. Despite these differences, the design and requirements are harmonized to reduce complexity and ensure seamless performance. This paper outlines the design strategies employed to achieve these objectives.
Momen, Faizul, Jensen, William, Das, Shuvajit, Chowdhury, Mazharul, Alam, Khorshed, Anwar, Mohammad, Reinhart, Timothy
Innovation Powered by High-Fidelity Multiphysics Modeling: A Holistic System Optimization of BorgWarner’s Next Generation Integrated Drive Modules2026-01-04974/7/2026
In the stringent market of BEV, the development of integrated Drive Modules (iDM) fitting environmental and customer needs is mandatory. It is important to extract the best from the less. To achieve those goals, a deep insight into complex multiphysics phenomena occurring in an iDM has been achieved by accurate and validated models. This engineering methodology is applied through the development of BorgWarner products, comprising non-exhaustively iDM 180-HF, Externally Excited Synchronous Machine and Multi-Level Inverter. The paper will review the methodology development for deeper understanding involving in-house technical excellence and complemented by strategic partnerships with academic institutions and start-ups. It will present the approach of integrating advanced multiphysics models with high-quality experimental validations, specifically on loss evaluation on electrical machines and inverters. Complex models involving multiphysics such as thermal/fluid coupling or electric-magnetic-mechanical behaviors are usually difficult to optimize separately since their objectives are often contradictory. Thus, BorgWarner PDS Engineering uses tools involving close coupling to optimize iDM products. The lecture will focus on innovation and optimization which are supported by several key pillars in the scope of a Next Generation iDM development. These are based on the following strategic levers such as process and design development, material development and control strategy among others. This ensures tailoring all components at the best of their capabilities to reduce their weight and maximize their use. Finally, the results achieved by the high-fidelity model-based optimization on the selected example will be presented (e.g., impact of the cooling improvement on overall iDM performances), demonstrating the benefit of capturing the system from granular view to a helicopter view in the design phase of next generation eDrives.
Leblay, Arnaud, Bourniche, Eric, Bossi, Adrien, David, Pascal, Nanjundaswamy, Harsha
Noninvasive Loss Breakdown of an Electric Drive Unit2026-01-04484/7/2026
Techniques exist to precisely measure the electromechanical efficiency in an electric drive unit (EDU), defined here as the combined motor and geartrain. While total drive-unit efficiency is an important metric, it does not quantify the different loss sources in the EDU. Due to the tight packaging in production EDUs, it’s impractical to mount a torque transducer between the electric machine and gearbox to separate the losses due to these components. Additionally, this approach does not separate the winding, core, and mechanical losses present in the machine. In this work, we developed a noninvasive approach to distinguish winding, core, and mechanical losses for EDUs containing synchronous electric machines. To separate the effects of these losses, mechanical output power was held constant at several test points while varying the stator’s current amplitude and angle. By maintaining the mechanical power at a constant value and varying the stator current, the core and winding losses were excited independently of the mechanical loss. We combined the resulting data with an equivalent-circuit model (ECM), including separate resistors representing the winding and core losses, as well as a flux-linkage map (providing the voltage for the ECM) to separate and quantify the individual losses. As validation, we implemented this approach on a 2022 Ford F-150 Lightning rear EDU. The Lightning EDU showed lower total efficiency during regenerative operation, rather than tractive, which is unusual, since core losses are typically lower when generating rather than motoring. The loss breakdown revealed that the machine’s core losses exhibited the usual behavior and that its winding losses were symmetric about zero torque, as expected. The EDU’s greater overall loss when generating was solely due to asymmetrical mechanical losses.
Woods, Tyler, Gross, Michael, Drallmeier, Joseph
Lightweight Bubble Sheet Panel To Reduce Inverter Noise and Vibration for Electric Vehicles2026-01-04424/7/2026
Inverters are typically integrated into electric drive units for electric vehicles (EVs) to reduce packaging size and cost. However, coupled vibrations from the electric motor and gears are transmitted to the inverter, which can become a dominant noise source due to its large radiative panel. Metal panels are required for electromagnetic interference (EMI) compliance, yet these covers usually lack sufficient stiffness or damping for noise control. Adding ribs and applying damping treatments result in excessive mass, cost, and packaging challenges. A new bubble sheet panel design has been developed to enhance the structural strength and damping performance of the inverter cover while significantly reducing its mass. A thin sheet of aluminum is welded onto the cover in an optimized pattern that enhances stiffness and damping performance while accommodating packaging requirements. The welding pattern can include logos or artistic designs to improve the panel’s appearance. The metal sheets are blown apart between the welds to form a 3D structure that is three times stiffer and twice as strong as a flat monolithic sheet of the same thickness. The composite dual bubble sheets can effectively reduce structural vibration. Damping materials, such as liquid-applied sound deadener (LASD), can be injected into the bubble sheet cavities to significantly improve its damping performance. Prototype bubble sheets have been designed, analyzed, and tested for an integrated inverter used in front-wheel-drive (FWD) electric drive unit for EV applications. Analysis and modal tests show a reduction of 10 to 15 dB at panel resonances with close to 30% reduction in mass. The bubble sheet panel is installed on an integrated inverter and tested in the electric drive unit. Sound power measurements confirm a reduction of up to 10 dB in inverter panel vibration.
He, Song, Bobel, Andrew, Naismith, Gregory, Yi, Wenwen, Patruni, Pavan Kumar
Quantum Eyes on Energy Loss: Diamond Quantum Imaging for Next-Gen Power ElectronicsTBMG-548814/1/2026
Improving energy conversion efficiency in power electronics is vital for a sustainable society. Wide-bandgap semiconductors like GaN and SiC power devices offer advantages due to their high-frequency capabilities. However, energy losses in passive components at high frequencies hinder efficiency and miniaturization. This underscores the need for advanced soft magnetic materials with lower energy losses.
CES 2026: AI, EVs Need These Power Electronics UpdatesTBMG-548604/1/2026
Physical AI may have been the dominant keyword at CES 2026, but behind all the hype around that, there were still plenty of companies on hand in Las Vegas focused on less flashy headlines. Here are some examples of companies working on the power electronics required behind the scenes to make our potential artificial intelligence future possible.
The Study on Alternative Switching Noise Caused by Pulsating Magnetic Field Off Direct Current Ripple Induced by the Invertor Switching2026-01-50223/30/2026
As already well-understood/enormous engineering practices, the inverter AC-side NVH phenomena/mechanisms/measures for motor-equipped vehicle, are already pretty clear. In addition to inverter AC side–induced NVH issues, DC ripple induced by PE switching leads to NVH issues manifesting on the capacitor, inductor, and conductor in terms of reverse piezoelectricity, electrostriction, magnetostriction, Laplace force, and so forth. These DC-side NVH issues are already literally analyzed by a couple of literatures, and mechanisms/measures are explored/applied to electric drive development. And yet, the phenomenon that a pulsating magnetic field inside a battery pack induced by DC current ripple off PE switching brings noise at switching frequency inside the vehicle cabin is newly captured/analyzed by our research, and that has been barely searched during the literature survey. This newly discovered phenomenon is the pivotal point in this paper. Although the noise features like the conventional switching noise that originates at the AC side of the inverter, the mechanism/measures are different; hence, this newly found NVH phenomenon is termed as alternative switching noise by the author, distinguishing itself from the conventional switching noise off AC side of the inverter. The mechanisms and measures associated with this phenomenon are innovatively explored/analyzed, which ultimately offer great aid to BEV/HEV/PHEV NVH interpretation/development. First, in this paper the inverter AC-side NVH issues are overviewed including mechanisms/measures, then DC-side NVH issues from capacitor, inductor, and conductor are reviewed in terms of mechanisms/measures, third the extending exploration/study upon alternative switching noise is described in detail. The relevant analysis for alternative switching noise is barely mentioned/involved during literature survey, and that is newly found/studied within the research delineated in this paper. Fourth, two case studies are exemplified to further validate the mechanisms/measures employed during investigation. In the end, the common strategies addressing the alternative switching noise are summarized, which shall be adopted to keep issues from happening at the very beginning of vehicle development stage.
Zhao, Qian, Zhao, Yihan, Niu, Haolong, Li, Qiwei, Zhang, Wenchao, Xue, Hongbin, Cheng, Yanan, Li, Jing, Kang, Ming
Airport Electrical Power System HarmonicsAIR5387 (Current)2/17/2026
This SAE Aerospace Information Report (AIR) is intended to cover all airport 50 or 60 Hz electrical systems as well as all electrical utilization equipment that is attached to those systems.
AGE-3 Aircraft Ground Support Equipment Committee
Common Mode Voltage Reduction in Quasi-Z Source Inverter for Electric Vehicle Applications Using MBPWM Technique2026-28-01022/12/2026
Unlike traditional voltage source or current source inverters, ZSI/qZSI can boost and invert DC power in a single stage, making them attractive for applications like EVs where battery voltage may vary. Common mode Voltage (CMV) is the voltage between the neutral point of the motor and ground. High CMV in motor drive systems can cause: Higher leakage currents, Electromagnetic interference (EMI), Insulation stress, bearing currents, leading to premature motor failure. Reducing CMV is essential for reliable and safe EV operation. Pulse-width modulation (PWM) is used to control the QZSI output voltage. The QZSI offers several advantages over traditional inverters, including improved efficiency, reduced cost, and increased reliability. The proposed system is designed to reduce the CMV through a combination of passive LC filtering and shoot-through (ST) modulation techniques. The LC filter is designed to attenuate high-frequency components of the CMV while the ST modulation is used to discharge the CMV to the DC bus. MBPWM reduces the common mode voltage due to the optimized distribution of shoot through states across switching period compared to conventional SBPWM technique. So combining LC filtering with MBPWM effectively mitigate the common mode voltage in inverter fed electric drives. The performance of the proposed system is evaluated through simulations using MATLAB/Simulink. The results show that the proposed system can effectively reduce the CMV and voltage regulation of the QZSI output.
N, Kalaiarasi, R, Rajarajeswari, D, Anitha
Advanced Signal Domain Techniques for Real-Time Control and Prognostics in VTOL SystemsSM-2026-VLADA-52051/27/2026
Vertical Take-Off and Landing (VTOL) aircraft introduce complex monitoring challenges due to distributed propulsion, lightweight structures, and variable operating conditions. This paper presents advanced Frequency and Orders domain techniques that repurpose existing flight control, propulsion, and structural sensor data to enhance observability without additional instrumentation. By transforming vibration, acoustic, and electrical signals into frequency and order domains, the approach enables detection of harmonics, resonance, and fault signatures tied to rotor dynamics, supporting adaptive control and predictive maintenance. Beyond rotor systems, these techniques are equally effective for monitoring electric motor health, gearbox wear, bearing degradation, and structural coupling effects in composite airframes. They also provide insight into power electronics and thermal management systems by identifying spectral anomalies linked to electrical imbalance or cooling inefficiencies. Aggregated fleet data strengthens prognostic capabilities, enabling early detection of systemic issues and trend analysis. Applications include mitigating ground resonance and modal instabilities, as well as improving reliability of propulsion and structural subsystems. Integration into avionics emphasizes computational efficiency, scalability, and compliance with standards such as DO-160 [1], DO-178 [2], ARP4761 [3] and ARP4764 [4]. Simulation and bench testing confirm feasibility, demonstrating potential to enhance safety, reliability, and lifecycle cost for next-generation urban air mobility platforms.
LaRue, David
A Method to Improve the System Efficiency of an Electronic Drive Unit: Variable Switching Frequency-Loss Optimization2026-26-00621/16/2026
The design and improvement of electric motor and inverter systems is crucial for numerous industrial applications in electrical engineering. Accurately quantifying the amount of power lost during operation is a substantial challenge, despite the flexibility and widespread usage of these systems. Although it is typically used to assess the system’s efficiency, this does not adequately explain how or why power outages occur within these systems. This paper presents a new way to study power losses without focusing on efficiency. The goal is to explore and analyze the complex reasons behind power losses in both inverters and electric motors. The goal of this methodology is to systematically analyze the effect of the switching frequency on current ripple under varying operating conditions (i.e., different combinations of current and speed) and subsequently identify the optimum switching frequency for each case. In the end, the paper creates a complete model for understanding power losses—without relying on efficiency as a measure. This work shows how using analytical methods and computer tools can give a deeper insight into how inverter and induction motor systems lose power, offering a fresh approach to analyzing and improving these systems.
Banda, Gururaj, Sengar, Bhan
Optimization of Inverter Control Strategies for Improved Powertrain Efficiency Using E-Motor Emulation Platforms2026-26-05091/16/2026
As the brain and the core of the electric powertrain, the traction inverter is an essential part of electric vehicles (EVs). It controls the power conversion from DC to AC between the electric motor and the high-voltage battery to enable effective propulsion and regenerative braking. Strong and scalable inverter testing solutions are becoming more essential as EV adoption rises, particularly in developing nations like India. In India, traditional testing techniques that use actual batteries and e-motors present several difficulties, such as significant safety hazards, inadequate infrastructure, expensive battery prices, and a shortage of prototype-grade parts. This paper presents a comprehensive approach for traction inverter validation using the AVL Inverter TS™ system incorporating an advanced Power Hardware-in-the-Loop (PHiL) test system based on e-motor emulation technology. It enables safe, efficient, and reliable testing eradicating the need for actual batteries or mechanical loads. Testing across signal and power levels and the validation of both inverter hardware and software under real-world driving scenarios can be facilitated with proposed test system. Indian OEM challenges like reduction in battery development costs, ensuring high replication precision, and managing thermal and power instability in early-stage prototypes are primary focus areas for this test system. With the Inverter TS, various motor types (IM, EESM, PMSM), switching strategies, and SiC based 800V architectures with different control architectures can be emulated and validated, which can further be optimized for powertrain efficiency. Inverter efficiency maps can be derived and fast control strategy can be iterated which facilitates the the overall drivetrain optimization. This paper focus on how adopting such emulation test methodologies can help EV developers to overcome infrastructure gaps, reduce time-to-market, and enhance powertrain efficiency at a lower cost.
Mehrotra, Soumya, Chhabra, Rishabh
Multiphysics Analysis of Heat Sink Designs for Efficient Thermal Performance in Power Electronics Systems2026-26-04461/16/2026
The thermal management capability of power electronic (PE) systems has a critical impact on the performance and efficiency of electric, fuel cell, or hybrid vehicles. Bus bars, high resistance sensor devices, semiconductor switches, power capacitors are the primary components, which make a major contribution in total heat generation in electrical drive unit. As PE packaging sizes are projected to become smaller, the challenge of managing increased heat dissipation becomes more critical. This paper numerically compares six different cooling strategies to determine the best possible thermal management scenario. A coupled physics co-simulation framework is used to analyze a 35W motor inverter integrated with water cooled heat sink. A multi-physics finite element model, integrating fluid, electrical, and thermal fields, is employed to analyze heat generation within the PE system and the associated cooling mechanisms. The power losses from the inverter system are dynamically computed in 1-D simulation and fed to the multi-physics finite element model as input. The Cooper-Mikic-Yovanovich (CMY) correlation is used to simulate the contact losses between busbar connections. This model considers the effect of surface roughness and topology on the electrical and thermal contact resistances. This research improves the comprehension of optimized cooling techniques, demonstrating the best design with calibrated cooling parameters. Additionally, it presents an effective numerical procedure for analyzing PE cooling phenomena.
Singh, Praveen Kumar, Natarajan, Nesamani, Murali, Sariki
Driving Performance Impact Analysis on EV Components for Efficient, Safe, and Intelligent Mobility2026-26-06551/16/2026
Electric vehicles (EVs) are the cornerstone of sustainable transportation, but their performance and component longevity are heavily influenced by driving behaviors. This study proposes a comprehensive analytical framework to assess how different driving styles affect the operational health of key EV components such as the battery pack, motor, and DC-DC converter. Various driving styles such as aggressive, moderate, and economical are discriminated against using dynamic vehicle operation signatures including acceleration and braking intensity, turning profiles, and load variations. These behavioral patterns are reflected in the electrical responses, namely current and voltage waveforms across power electronic systems. By analyzing these electrical signatures, a range of KPIs can be estimated for each component, offering insights into their operational stress and degradation trends. Experimental analysis using real-time EV datasets validates the framework’s ability to predict and correlate driving patterns with component degradation trends. By evaluating these impacts, the study bridges the gap between driving behaviors and their consequences on EV performance in real-time operation. The research culminates in generating prescriptive and descriptive analytics, offering actionable insights and tailored recommendations for driving behavior improvement. Real-time suggestions empower drivers to adopt safer, more efficient styles, while actionable strategies provide a roadmap for EV manufacturers and policymakers to promote sustainable and efficient transportation systems. This study underscores the critical interplay between driving behavior and EV component health, paving the way for smarter, data-driven mobility solutions
Deole, Kaushik, Kumar, Pankaj, Hivarkar, Umesh
Multi-Physics Simulation and Reliability Analysis of Onboard EV Charger2026-26-04991/16/2026
The rapid advancement of electric vehicle (EV) technology has created a demand for reliable and Thermal - efficient electronic components for power electronics and control systems on printed circuit boards (PCBs). The research looks at the overall simulation and study of a PCB for Electric Vehicles, including how it handles heat, stress, and reliability in real working conditions like considering casing (Heat Sink) in which PCB is held, into the simulation. We have used numerical based methods (reliability), Finite Element Analysis (FEA) and Computational Fluid Dynamics (CFD) methods to simulate heat performance looking at steady-state and changing load profiles common in EV powertrains. We ran structural and thermal simulations to check the PCB's toughness against heat expansion and shaking loads often seen in cars. We also did a reliability check looking at heat cycling life for PCB components, and possible ways it could break to guess long-term toughness. The results show critical hot spots in the PCB design, structure warping from mechanical stress, and highlighted key things that affect how long the PCB components can lasts. Based on these simulations, we suggested some ways to manage heat, and structural rigidity, like selecting better materials and placing parts at smarter location. This study shows a step-by-step way to use multi-physics simulations early when designing EV PCBs leading to better heat control mechanical toughness, and overall system reliability.
Kanbarkar, Suraj Omana, Deore, Uday, Patil, Nishikant, Nayak, Shibabrata
Review of Conducted EMI by Different PWM Schemes in the EV Inverters2026-26-01811/16/2026
The advent of wide-bandgap (WBG) switching MOSFET devices enables high-frequency operation, allowing for significant reductions in the size of passive components such as inductors and capacitors, and improving the overall efficiency of inverter systems. However, these benefits come with the trade-off of increased electromagnetic interference (EMI), which imposes stringent requirements on filter design. The complexity of designing EMI filters, which depends heavily on switching frequency and applicable EMI standards, presents a significant challenge and can impact development timelines. Carrier wave modulation technique is considered as an effective method for minimizing conducted EMI in traction inverters. This article presents various carrier wave modulation schemes that successfully reduce conducted EMI. The evaluated strategies aim to eliminate noise fluctuations and simplify the design of demanding EMI filters. Additionally, the impact on output voltage, output current, total harmonic distortion, and overall inverter performance has been analyzed. The results demonstrate that the discussed carrier wave modulation techniques can reduce conducted EMI more efficiently than conventional carrier frequency PWM methods.
R, Kodeeswaran, Kuncham, Sateesh Kumar, Kolhatkar, Yashomani
SEooC- Based Design Framework Integrated EV Power Conversion Systems under ISO-26262 Compliance2026-26-01921/16/2026
The work completed on “System level concepts to test and design integrated EV system involving power conversion to satisfy ISO26262 functional safety requirement” is included in the paper. Integrating power conversion and traction inverter subsystems in EVs is currently popular since it increases dependability and improves efficiency and cost-effectiveness. Maintaining safety standards is at danger due to the growing safety requirements, which also raise manufacturing costs and time. The three primary components of integrated EV systems are the PDU, DC-DC converter, and onboard charger. Every part and piece of software is always changing and needs to be tested and validated in an economical way. Since the failure of any one of these components could lead to a disaster, the article outlines the economical approaches and testing techniques to verify and guarantee that the system meets the functional safety criterion.
Uthaman, Sreekumar, Mulay, Abhijit B, Gadekar, Pundlik
Model Standardization for MBD throughout Entire Power Unit Development Process2026-26-04281/16/2026
The distribution of mobility equipped with electrified power units is advancing towards carbon-neutral society. The electrified power units require an integration of numerous hardware components and large-scale software to optimize high-performance system. Additionally, a value-enhancement cycle of mobility needs to be accelerated more than ever. The challenge is to achieve high-quality performance and high-efficient development using Model-Based Development (MBD). The development process based on V-model has been applied to electrified power units in passenger vehicle. Traditionally, MBD has been primarily utilized in the left bank (performance design phase) of the V-model for power unit development. MBD in performance design phase has been widely implemented in research and development because it refines prototype performance and reduces the number of prototypes. However, applying the MBD to an entire power unit development process from performance design phase to performance verification phase is not achieved. This is because 1D models constructed during the performance design phase with the MBD are not intended for use in the performance verification phase. As a result, the MBD effect is insufficient for the high-efficient development. Therefore, uses of 1D models that made at the performance design phase for the left bank should be enhanced. In particular, the 1D system model that integrated sub-systems is important for applying the MBD to the verification phase. The 1D system model is able to use for a virtual calibration of control of a vehicle system. In addition, the verification with Hardware-in-the-Loop Simulation (HILS), Engine-in-the-Loop (EIL), and Power unit-in-the-Loop (PIL) is also achieved smoothly by using the sub-system models in the 1D system model. The 1D system model standardization is necessary for achieving the above high-efficient development process. This paper explains efforts to the standardize model assuming the use of MBD throughout the entire power unit development process and practical efforts of both performance design phase and the verification phase using the standardized model.
Ogata, Kenichiro, Katsuura, Akihiro, Tsuji, Minako, Matsumoto, Takumi, Iwase, Hiromu, Nakasako, Seiya, Takahata, Motoki
Development of an Optimized XCP Software Stack for Real-Time Validation of Vehicle Control Units Using Next-Generation Communication Protocols2026-26-01901/16/2026
With the rapid adoption of electric vehicles (EVs), ensuring the reliability, safety, and cost-effectiveness of power electronic subsystems such as onboard chargers, DC-DC converters, and vehicle control units (VCUs) has become a critical engineering focus. These components require thorough validation using precise calibration and communication protocols. This paper presents the development and implementation of an optimized software stack for the Universal Measurement and Calibration Protocol (XCP), aimed at real-time validation of VCUs using next-generation communication methods such as CAN, CAN-FD, and Ethernet. The stack facilitates read/write access to the ECU’s internal memory in runtime, enabling efficient diagnostics, calibration, and parameter tuning without hardware modifications. It is designed to be modular, platform-independent, and compatible with microcontrollers across different EV platforms. By utilizing the ASAM-compliant protocol architecture, the proposed system significantly reduces dependency on expensive proprietary tools, offering a cost-effective alternative for the Indian EV industry.
Uthaman, Sreekumar
Thermal System Design of Inter-City Fuel Cell Electric Bus2026-26-04271/16/2026
In current scenario, demand for alternate energy is increasing due to depletion of fossil fuels and countries working to achieve carbon neutrality by 2050. Hydrogen being a cleaner fuel, many OEMs across the world started to work on various strategies like hydrogen combustion engine and fuel cell. Passenger vehicles like buses are at the lookout for fuel cell technology at faster rate than other commercial vehicles. In fuel cell vehicles, cooling system design is critical & complex since it includes fuel cell cooling, Power electronics cooling & battery cooling. In this paper, cooling system design of a Fuel cell electric bus for inter-city application is demonstrated. Radiators and Fans are designed considering overall heat rejection and Coolant inlet temperature requirements of components. Cooling system circuit and pump is decided to meet the coolant flow rate targets. Flow simulation and thermal simulation done with the help of simulation models built using software KULI to predict coolant flow rate and temperature across each component. Fuel cell circuits, Power electronic circuits, Battery circuits modelled in KULI with all components in the circuit. KULI predicted results signifies good co-relation with actual results.
M S, Vignesh, Kiran, Nalavadath
Review on the Flyback Converter Design for Multi-Output2026-26-02001/16/2026
With the increasing demand for DC loads, DC-DC converters have become indispensable in modern power electronic architectures. With high-voltage applications typical DC-DC converter topologies are required which include isolation for safety and voltage level conversion. Among various isolated converter topologies, the flyback converter is widely favored for low-power applications, typically under 100 W, due to its simplicity and cost-effectiveness. Like other DC-DC topologies, the flyback converter can operate in either continuous conduction mode or discontinuous conduction mode (DCM). The work has focused on the design and performance analysis of a flyback converter operating in DCM, with a specific emphasis on magnetic component design and loss evaluation. A 55 W multi-winding flyback converter employing a passive snubber circuit is studied and implemented. The loss analysis is done with switch losses around 3.4W and the coupled inductor core losses around 1.5W and copper losses around 0.8W. Furthermore, a comparative analysis of passive voltage clamping techniques is presented to address voltage spikes across the primary switch. The most common passive snubbing techniques in the primary side switch node which includes the Resistor Capacitor Diode Clamping and Transient Voltage Suppressor Diode clamping is discussed. Using LTspice, an open-loop simulation is developed to validate operation. The necessity of primary snubbing and the implementation of valley switching are described and validated through simulation results. A hardware prototype is developed to validate the same for the input voltage varying from 90V to 400V, and with three output voltage of 12V, 16V and 18V.
S, Denis, Deshpande, Prathamesh Pravin, Deshpande, Rohan
Totem-Pole PFC and LLC Resonant Converter based 6.6kW On-Board Charger for LEV Applications2026-26-01601/16/2026
As light electric vehicles (LEVs) gain popularity, the development of efficient and compact on-board chargers (OBCs) has become a critical area of focus in power electronics. Conventional AC-DC topologies often face challenges, including high inrush currents during startup, which can stress components and affect system reliability. Furthermore, DC-DC converters often have a limited soft-switching range under light load conditions, leading to increased switching losses and reduced efficiency. This paper proposes a novel 6.6 kW on-board charger architecture comprising a bridgeless totem-pole power factor correction (PFC) stage and an isolated LLC resonant DC-DC converter. The main contribution lies in the specific focus on enhancing startup behavior and switching performance. In PFC converters, limiting inrush current during startup is crucial, especially with fast-switching wide-bandgap devices like SiC or GaN. Conventional soft-start techniques fall short in of ensuring smooth voltage transitions. Moreover, maintaining stable operation across a universal input voltage range and achieving a high-power factor under light load conditions remain persistent challenges. Although resonant converters are widely used for their natural soft-switching ability, achieving zero voltage switching (ZVS) over a wide range of loads, especially at light load conditions, is still a technical challenge. Existing solutions rely on complex control strategies or hardware modifications, which increase cost and design complexity. The proposed architecture was modeled and simulated using MATLAB/Simscape to assess dynamic and steady-state behavior under a range of operating conditions. Results demonstrated high input power factor, line/load regulation, and switch-node waveforms to confirm ZVS operation. Additionally, the proposed charger exhibits low harmonic distortion, ensuring compliance with IEC 61000-3-2 power quality standards. These findings confirm the topology’s effectiveness for high-performance LEV charging and set a strong foundation for future experimental validation and hardware development.
Patil, Amruta, Bagade, Aniket
Advanced SVPWM Techniques for Multi-Level Inverters: Enhancing Performance and Reducing Complexity2026-26-01471/16/2026
Over the last few years, notable progress has occurred in electric vehicle (EV) technology. Inverters are key components for electric vehicles (EV). Various PWM strategies have been implemented by OEMs over past years. For most of PWM scheme timing calculation & Lengthy algorithm increases complexity. The proposed a novel Pulse Width Modulation (PWM) control technique for generating inverter lag switching times in multi-level inverters. The proposed Space Vector PWM (SVPWM) method eliminates the need for sector and region identification by utilizing sampled values of reference phase voltages, thereby reducing computational efforts and complexities. The scheme can generate N-level PWM signals and offers flexibility to operate with fewer levels, including operation in the overmodulation range. The sampled magnitudes reference phase voltages are converted into timing signals that are subsequently processed by an algorithm to modify modulating signals. These modulating signals are individually decoded to generate PWM pulses for each phase, making the scheme applicable towards any multilevel inverter configuration. The timing signals are applied to a five-level inverter formed by cascading two three-level inverters. The performance of the inverter is validated using an induction motor drive with open-end winding, with simulations conducted in MATLAB and Simulink software.
Bhanabhagvanwala, Prem Kiritkumar
Correlation of Power Rating for Battery Electric Vehicles: Simulation vs. Test Validation in Accordance with Regulatory Compliance2026-26-05751/16/2026
Accurate power and energy assessment in Battery Electric Vehicles (BEVs) requires high-fidelity simulation models that reflect real-world performance. This study presents a power rating correlation of the BEV model in compliance with the GTR 21[1] standard, validating the simulation’s accuracy against physical test data. Simulations were conducted using Matlab and Simulink based Simulation tool to estimate Electric Drive Module (EDM) power at the motor output and gearbox input under standardized conditions. The operating parameters were shared with the testing team to ensure consistency; however, the initial test results deviated by approximately 4% to 5% from the simulation target. To address this delta, EDM speed and vehicle speed were optimized, achieving a close alignment with the simulation and meeting the power rating targets. The results demonstrate a strong correlation between the simulation and test data, confirming the model’s accuracy and reliability. This study underscores the effectiveness of simulation-based validation in enhancing BEV power rating predictions, reducing physical testing dependencies, and accelerating vehicle development cycles while ensuring regulatory compliance.
Mahajan, Prasad, Kesarkar, Sidhesh, Ali, Shoaib
Modeling and Analysis of Transient Behavior of Surge Protective Devices in Electric Vehicle Charging Systems2026-26-01781/16/2026
This paper introduces a modeling and simulation methodology for transient analysis of surge protective devices (SPDs) for electric vehicle charging system (EVCS) application. The suggested Surge Protective Device topology is to shield the EV power electronics such as on board charger from surge events generated by the grid during charging, with implementation on the grid-EV interface. A new surge protection circuit is designed to suppress transient overvoltages, with its performance evaluated through simulation. The SPD is evaluated in SPICE simulator in the time domain, including its nonlinear spark over characteristics along with its resistive, capacitive and inductive effects. Equivalent circuit is developed and evaluated by simulation under typical surge conditions. The outcomes prove the topology to be effective in clamping voltage, reducing energy transfer to the EV side, and achieving surge event detection. The contribution of this work lies in the establishment of dependable and smart surge protection systems for secure and resilient EV charging infrastructure.
CHANCHAL, Kumar Prem Chandra, Kulkarni, Swanand, Rajaram Joshi, Sanjay, Patil, Sagar
DC Link Capacitor Size Reduction Using Phase-Shifted PWM Techniques for Pole-Phase Modulated Induction Machine Drives2026-26-01701/16/2026
This manuscript introduces a methodology to reduce the DC link capacitor size in pole-phase modulated (PPM) induction motor drives (IMD). Typically, the DC link capacitor (DCLC) occupies around 25 to 30% of the inverter volume and 20% of the inverter material cost. Reducing the DCLC size and cost is essential to lowering the inverter size and cost. This can be accomplished by lowering the DCLC ripple current. The proposed technique suggests adapting phase-shifted triangular carrier waveforms, in all the operating modes of the PPM drive, to significantly reduce the ripple current through DCLC, successively reduces the size and cost of DCLC. Simulations are performed in MATLAB/Simulink on a 9 phase PPM drive to validate the efficacy of the strategy. Though the suggested concept is verified with a 9 phase PPM drive, which is operated in 2 modes, it can be extended to any 3n PPM drive. The results demonstrate a 60% reduction in ripple magnitude, enabling the use of smaller, more reliable, and cost-effective capacitors.
A, Rajeshwari
Horse Powertrain's Future Hybrid System can hybridize EVs25AUTP12_0512/1/2025
Horse Powertrain revealed more information about its all-in-one hybrid powertrain, the Future Hybrid System, at IAA Mobility 2025 in Munich in September. The new details involve a 1.5-L, four-cylinder unit with integrated engine, motor, and transmission that was designed to replace an EV's front electric drive module to convert that EV into a hybrid, PHEV, or range-extended EV. Horse Powertrain revealed two variants of the Future Hybrid System (FHS) in Munich. The first, called Performance, is 740 mm (29 in) wide and uses two motors in a P1 + P3 configuration, with one each on the engine output and transmission output shafts. The second, the Ultra-Compact, is 650 mm (26 in) wide and is designed to sit between the engine and transmission. The 1.5-L engine, a dedicated hybrid transmission, and a full suite of power electronics for hybrid use are used in both versions. The company said an even smaller version - by 70 mm (3 in) - with three cylinders is being investigated.
Blanco, Sebastian
Thermal Model of a Traction Inverter for an Automotive Application, Including DC-Link Capacitor, Power Modules and Electrical Connections2025-01-051911/25/2025
In automotive applications a power electronic converter is used for energy conversion between battery and electrical machine. For high performance drives a lightweight design is demanded. Additionally, a higher efficiency of the inverter results in lower cooling requirements but is often achieved by increasing component weight. Hence, thermal modeling of the components and their interactions is essential to determine the best compromise between weight, efficiency and cooling requirements. In traction inverters the DC-link capacitors, power modules, high voltage electrical connections and low voltage devices dissipate power. In this paper the focus is on the thermal modeling of the DC-link capacitor, power modules and high voltage electrical connections and their system, as the performance of the inverter is defined by these components. The thermal models are derived based on physical properties and geometries. First, the DC-link capacitor thermal model is presented and considers the anisotropic heat conductivity of the capacitor coil and the inhomogeneous loss feeding in the busbars. Next, the thermal model of a power module and heatsink is explained taking temperature dependent material properties into account. Based on the input temperature of the coolant and heat dissipation of the power modules the temperature rise of the fluid is calculated. Furthermore, the electrical connections, consisting of a combination of cables, busbars and shunts are thermally modeled. With the individual component models combined an overall inverter thermal model is developed. A comparison between the thermal system model and measurements is carried out finally. For this several temperature sensors were integrated into an inverter. By taking the measured temperatures into account, the thermal system model is validated for stationary and dynamic load points. As all models are based on geometric and material properties it is possible to observe the impact of sizing in the future.
Blaschke, Wolfgang Maximilian, Mengoni, Leonard, Pflüger, Robin, Kulzer, André Casal
Analysis of Factors Influencing the Efficiency Improvement Potential of a Winding Changeover in an Electric Machine2025-01-051811/25/2025
The winding configuration of an electric machine has a decisive influence on the properties of a traction drive. When designing the electric drive, the optimum compromise must be found between maximum torque, maximum power and high efficiency over a wide operating range. A decisive factor in this design conflict is the choice of the winding configuration. The concept of winding switching offers a way of solving the design conflict and improving the characteristics of the drive through the additional degree of freedom of the variable winding configuration. Switching the number of parallel winding branches in a serial and parallel configuration is a promising approach to overcome the challenge of a high spread between maximum power and high efficiency in customer related driving scenarios of an electric vehicle. The aim of this study is to identify factors influencing the efficiency improvement potential of the winding switching topology under consideration compared to a reference drive without winding switching. For this purpose, a sensitivity analysis of various parameters of the electric drive consisting of the inverter and the electric machine is carried out with regard to increasing efficiency in customer related driving scenarios. The effects of winding switching are described in relation to the influencing factors of rotor design, active length of the electric machine, star/delta winding connection and the inverter design. The conditions of an electric drive under which a winding changeover offers efficiency advantages in the customer related driving range are to be derived from the findings on the influencing factors and the effects of a winding changeover.
Oestreicher, Raphael, Koenen, Christian, Kulzer, André Casal
A Scalable Approach for Transient Thermal Modeling of Automotive Power Electronics2025-01-507311/7/2025
Efficient thermal management is critical for the reliability and performance of power electronics systems in automotive applications. This work presents a computationally efficient modeling approach for transient thermal simulation of power electronic systems, with a focus on inverter modules using multiple MOSFETs mounted on a printed circuit board assembly (PCBA). A case study of an inverter module comprising six MOSFETs arranged as high-side and low-side pairs for a three phases system mounted on a PCBA, attached to a heat sink is considered. Computational fluid dynamic (CFD) simulations in Ansys® Icepak™ are performed considering different heat transfer mechanisms, including natural convection, forced convection at constant velocity, and forced convection with varying flow velocity. A transient thermal model is developed using the lumped parameter linear superposition (LPLSP) method, a hybrid approach that combines lumped parameter modeling with the principle of linear superposition to capture transient thermal behavior efficiently. Temperatures of the components from the simulations are compared with temperatures from the LPLSP model and temperatures from a linear time invariant (LTI)–based reduced-order model (ROM) developed for this system. It is observed that the LPLSP model is able to model a wide range of use cases very accurately with error of less than 5%. This method enables rapid thermal performance evaluation of power electronics systems that have very fast transients in component-level power dissipation and variations in ambient conditions, making it particularly well-suited for early stage design iterations and long-duration mission profile simulations. The approach offers a practical path to reducing development cycles for automotive power electronics design.
Padmanabhan, Neelakantan
Power Electronics: The Backbone of Sustainable Electrification2025-28-022811/6/2025
Power electronics are fundamental to sustainable electrification, enhancing energy, efficiency, integrating renewable energy sources, and reducing carbon emissions. In electric vehicles (EVs), power electronics is crucial for efficient energy conversion, management, and distribution. Key components like inverters, rectifiers, and DC-DC converters optimize power from renewable sources to meet EV system requirements. In EVs, power electronics convert energy from the lithium-ion battery to the electric vehicle motor, with sufficient propulsion and regenerative braking. Inverters is used to transfer DC power from the lithium-ion eEV battery to alternating current for the motor, while DC-DC converters manage voltage levels for various vehicle systems. These components maximize EV energy efficiency, reduce energy losses, and extend driving range. Power electronics also support fast and efficient battery charging, critical for widespread EV adoption. Advanced charging solutions enable rapid charging times and connecting with renewable energy sources, enhancing transportation sustainability. Vehicle to grid (V2G) capabilities allow Electric vehicles to act as storage devices, providing grid support and contributing to energy stability. Key components in EVs include wide band semiconductors like Silicon Carbide and Gallium Nitride, which offer superior efficiency, higher temperature tolerance, and better thermal management compared to current silicon semiconductors. These materials are effective in high-power applications and revolutionize power electronics technologies. In summary, power electronics is necessary for integrating renewable energy, electrifying transportation, and optimizing energy use in EVs. Its impact drives the transition to a low-carbon future and supports the sustainability of modern transportation systems.
Pipaliya, Akash Pravinbhai, Hatkar, Chetan
Challenges in Transitioning from 400V to 800V Off-Highway Power Electronics2025-28-028111/6/2025
Electrification applications are increasingly moving towards higher voltage systems to enable greater power delivery and faster battery charging. This trend is particularly evident in the shift from 400V to 800V systems, which offers several benefits and poses unique technical challenges. Higher voltage systems reduce current flow, minimizing energy losses, and improving overall efficiency. This is crucial for applications like electric vehicles and off-highway machinery, where efficient power management is essential. One of the primary benefits of increasing the DC link voltage beyond the 400V is the ability to support higher power levels. Additionally, higher voltage systems can reduce the size and weight of power components, contributing to more compact and lightweight designs. However, transitioning to 800V systems introduces several technical challenges in power electronics design. Key components such as power components (IGBT, MOSFET etc.) must be optimized to handle higher voltages and currents, requiring advanced thermal management solutions to dissipate the increased heat generated. Insulation and isolation for PCB design become more critical at higher voltages, necessitating robust insulation materials and techniques to prevent electrical breakdowns and ensure safety. Gate drivers and digital isolators must handle high-frequency transients and maintain reliable operation in high-voltage environments. A comprehensive review of these critical components and their reliability aspects is essential for the successful implementation of 800V systems in electrification applications. Addressing these challenges through innovative design and advanced materials will pave the way for more efficient, reliable, and high-performance power electronics solutions.
Hatkar, Chetan Manohar, Pipaliya, Akash
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