Browse Topic: Power electronics

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Common Mode Voltage Reduction in Quasi-Z Source Inverter for Electric Vehicle Applications Using MBPWM Technique2026-28-0102To be published on 02/01/2026
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
N, Kalaiarasi, R, Rajarajeswari, D, Anitha
Surrogate modeling for faster assessment of thermal performance and reliability of discrete packaging in power electronics2026-28-0100To be published on 02/01/2026
The thermal performance and reliability of discrete packaging in power electronics are critical due to miniaturization and high-density packaging. Optimizing solder joint design is essential to mitigate thermo-mechanical fatigue, a primary failure mechanism caused by repeated thermal cycling in power switching applications like MOSFET packages. This cycling leads to uneven expansion and contraction among materials, potentially resulting in cracks that impair heat dissipation or cause delamination. While physics-based finite element modeling (FEM) is effective for predicting solder joint lifetimes, it can be resource-intensive and slow during the conceptual design phase, where rapid decision-making is crucial. This paper introduces a surrogate modeling approach to deliver faster, data-driven solutions in early design stages. By employing a finite element-based virtual design of experiments (VDoE), the study analyzes multiple design parameters, such as thermal interface material (TIM
Naga Satyakrishna, Vinjamuri, Baikadi, Pawan Rao, Gromala, Przemyslaw
Thermal System design of Inter-City Fuel Cell Electric Bus2026-26-0427To be published on 01/16/2026
In the current scenario, demand for alternate energy is increasing due to depletion of fossil fuels and countries commitment towards carbon neutrality by 2050. Hydrogen is considered as one of the cleaner fuels and 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 selected based on the 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 using simulation models using software KULI
M S, Vignesh, Kiran, Nalavadath
Modeling and Analysis of Transient Behavior of Surge Protective Devices in Electric Vehicle Charging Systems2026-26-0178To be published on 01/16/2026
This paper introduces a modeling and experimentation methodology for transient analysis of surge protective devices (SPDs) for electric vehicle (EV) application. The suggested SPD topology is to shield the EV power electronics 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 over voltages and allow real-time monitoring of surge conditions. The SPD is evaluated in SPICE simulator in the time domain, including its nonlinear spark over characteristics as well as resistive, inductive, and capacitive effects. The 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
CHANCHAL, Kumar Prem Chandra, Kulkarni, Swanand, Rajaram Joshi, Sanjay, Patil, Sagar
Review on Conducted EMI by different PWM schemes in the EV Inverters2026-26-0181To be published on 01/16/2026
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
R, Kodeeswaran, Kuncham, Sateesh Kumar, Kolhatkar, Yashomani
Performance Analysis of Filter Resistance, Louver Airflow, and Fan Heat Dissipation to protect Swapping station Charger2026-26-0177To be published on 01/16/2026
Efficient thermal management in electric vehicle (EV) charging stations is critical for ensuring the reliability, safety, and longevity of power electronics. This study presents a comprehensive bench test analysis of three key parameters influencing charger cooling efficiency: filter resistance, louver airflow, and fan heat dissipation. A test bench was developed to measure pressure drop, temperature gradients, and air velocity variations across multiple filter types, louver orientations, and fan configurations. The results show that higher-efficiency filters (e.g., HEPA, MERV13) significantly reduce airflow, increasing thermal stress on electronic components, while optimized louver angles improve directional airflow, reduce turbulence, and enhance cooling performance. High-performance axial and centrifugal fans with adaptive control mechanisms further contribute to effective heat dissipation, maintaining stable operating temperatures under varying load conditions. This study provides
S, Sri Saran, chinnanna, Manjunath, Ajith, Arjun, B, Viswanathan, Kulkarni, Mukund, R, Vigneshwaran, Dhachinamoorthi, Sivanantham
Multi-Physics Simulation and Reliability Analysis of Onboard EV Charger2026-26-0499To be published on 01/16/2026
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
Kanbarkar, Suraj Omana, Deore, Uday, Patil, Nishikant, Nayak, Shibabrata
Optimization of Inverter Control Strategies for Improved Powertrain Efficiency Using E-Motor Emulation Platforms2026-26-0509To be published on 01/16/2026
The traction inverter is a critical component in electric vehicles (EVs), functioning as the heart and brain of the electric powertrain. It controls the power conversion between the high-voltage battery and the electric motor, enabling efficient propulsion and regenerative braking. As EV adoption grows, especially in emerging markets like India, the need for robust and scalable inverter testing solutions becomes paramount. Traditional testing methods involving real batteries and e-motors pose several challenges in the Indian context, including high safety risks, infrastructure limitations, high battery costs, and limited availability of prototype-grade components. This paper presents a comprehensive approach to inverter validation using the AVL Inverter TS™ system— an advanced Power Hardware-in-the-Loop (PHiL) test system based on e-motor emulation technology.. It enables safe, efficient, and reliable testing without the need for actual batteries or mechanical loads. The system
Mehrotra, Soumya, Chhabra, Rishabh
Advanced SVPWM Techniques for Multi-Level Inverters: Enhancing Performance and Reducing Complexity2026-26-0147To be published on 01/16/2026
Recent advancements in electric vehicle (EV) technology have underscored the critical role of inverters. Traditional Pulse Width Modulation (PWM) schemes, commonly used by Original Equipment Manufacturers (OEMs), involve complex timing calculations and lengthy algorithms. This scheme proposes a novel method that eliminates the need for sector and region identification by utilizing sampled values of reference phase voltages, thereby reducing computational efforts and complexities. The proposed scheme can generate N-level PWM signals and offers the flexibility to operate with fewer levels, including in the overmodulation range. The process begins with the conversion of sampled reference phase voltages into timing signals. These timing signals are then processed by an algorithm designed to modify the modulating signals. The modulating signals are individually decoded to generate PWM pulses for each phase, making the scheme applicable to any multilevel inverter configuration. This
Bhanabhagvanwala, Prem Kiritkumar
Driving performance impact analysis on EV components for efficient, safe, and intelligent mobility2026-26-0655To be published on 01/16/2026
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
Deole, Kaushik, Kumar, Pankaj, Hivarkar, Umesh
A Method to Improve the System Efficiency of an Electronic Drive Unit: Variable Switching Frequency-Loss Optimization2026-26-0062To be published on 01/16/2026
In electrical engineering, designing and improving inverter and induction motor systems is very important for many industrial uses. Even though these systems are flexible and widely used, one of the main challenges is accurately measuring how much power is lost when they run. Usually, people check the system’s efficiency, but that doesn’t fully explain how or why the power loss happens inside these systems. This paper presents a new way to study power losses without focusing on efficiency. Instead, it uses analytical methods supported by MATLAB programming. The goal is to explore the complex reasons behind power losses in both inverters and induction motors. To do this, the study develops mathematical formulas that describe the different types of losses, such as those from conduction, switching, and magnetic effects. These formulas are based on basic physics and are turned into MATLAB code, which helps connect theory with real-world application. In the end, the project creates a
Banda, Gururaj, Sengar, Bhan
Correlation of Power Rating for Battery Electric Vehicles Simulation vs. Test Validation in Accordance with regulatory compliance2026-26-0575To be published on 01/16/2026
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 Stellantis Dodge model in compliance with the GTR 21 standard, validating the simulation’s accuracy against physical test data. Simulations conducted using STLAsim, Stellantis’ proprietary tool, estimate EDM power at the inverter input and axle output under standardized conditions. The operating parameters were shared with the testing team to ensure consistency; however, the initial test results deviated by approximately 18 kW 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 GTR 21 power rating criteria. 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
Mahajan, Prasad, Kesarkar, Sidhesh, Ali, Shoaib
Multiphysics Analysis of Heat Sink Designs for Efficient Thermal Performance in Power Electronics Systems2026-26-0446To be published on 01/16/2026
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 has 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. Hence, this paper numerically compares conventional and advanced cooling strategies to determine the best possible thermal management scenario. A multi-physics finite element model, integrating fluid, electrical, thermal, and structural fields, is employed to analyze heat generation within the PE system and the associated cooling mechanisms. Due to the significant impact of surface roughness and topology on electrical and thermal contact resistance, the Cooper-Mikic-Yovanovich (CMY) correlation is utilized
Singh, Praveen Kumar, Natarajan, Nesamani, Murali, Sariki
Totem-Pole PFC and LLC resonant converter based 6.6kW On-Board Charger for LEV Applications2026-26-0160To be published on 01/16/2026
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
Patil, Amruta, Bagade, Aniket
DC Link Capacitor Size Reduction Using Phase-Shifted PWM Techniques for Pole Phase Modulated Induction Machine Drive2026-26-0170To be published on 01/16/2026
Multiphase machines i.e. electrical machines with more than three phases have many advantages compared to the three-phase machines for high power density applications. The major advantages of multiphase machines include lower space harmonics thereby reduced losses and improved efficiency, reduced torque pulsations leading to lesser vibrations and acoustical noise, higher fault tolerance which retains the self-starting ability with minimum deration in the output power in case of fault in one or more phases and enhancement of torque density by adding higher order harmonic currents into the stator currents. Requirement of power electronic switches with reduced rating compared three phase motor drives for a given power rating is another important advantage which supports employing multiphase machines in high power applications. Wider speed and torque ranges are other important requirements of a drive for high power traction and propulsion application. Conventional machines need to be over
A, Rajeshwari
SEooC-Based Design Framework for Integrated EV Power Conversion Systems under ISO 26262 Compliance2026-26-0192To be published on 01/16/2026
The rapid integration of electric vehicle (EV) power conversion elements—such as traction inverters, onboard chargers, and DC-DC converters—into unified architectures poses new challenges for ensuring functional safety compliance as per ISO 26262. This paper presents a system-level framework that leverages the Safety Element out of Context (SEooC) approach to design and validate reusable safety-critical components independent of vehicle-specific applications. By defining clear assumptions of use and ASIL decomposition strategies, the proposed method facilitates early-stage fault analysis and verification. The framework integrates model-based development with Hardware-in-the-Loop (HIL) testing and formal verification techniques to validate both control logic and hardware behavior under diverse fault injection scenarios. The result is a scalable, standards-compliant methodology that reduces time-to-market and enhances reliability in integrated EV power electronics platforms. The work
Uthaman, Sreekumar, Mulay, Abhijit B, Gadekar, Pundlik
Development of an Optimized XCP Software Stack for Real-Time Validation of Vehicle Control Units Using Next-Generation Communication Protocols2026-26-0190To be published on 01/16/2026
In EVs, todays trend is to integrate power conversion and traction inverter subsystems by ensuring the increase in reliability and improvement in efficiency and cost effectiveness. The increased safety requirement poses risk of maintaining safety standards and increase in cost and time for manufacturing. The main integrated EV systems consists of Onboard charger, DC -DC converter and PDU. Each of the components and software is continuously evolving and it requires to be tested and validated in cost effective manner. The paper describes the design and development of XCP (Universal Measurement and Calibration Protocol) software stack for connecting calibration systems to electronic control units. The Software stack help in the read and write variable in the memory content of the microcontroller at run time. It’s a network Protocol Originated From ASAM. The software stack is easy to understand and platform independent, allowing it to be used on any microcontroller
Uthaman, Sreekumar
Review on the flyback converter design for multi-output2026-26-0200To be published on 01/16/2026
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 have 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
S, Denis, Deshpande, Prathamesh Pravin, Deshpande, Rohan
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
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
Oestreicher, Raphael, Koenen, Christian, Kulzer, André Casal
A Scalable Approach for Transient Thermal Modeling of Automotive Power Electronics2025-01-507311/07/2025
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
Padmanabhan, Neelakantan
Power Electronics: The Backbone of Sustainable Electrification2025-28-022811/06/2025
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
Pipaliya, Akash Pravinbhai, Hatkar, Chetan
Challenges in Transitioning from 400V to 800V Off-Highway Power Electronics2025-28-028111/06/2025
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
Hatkar, Chetan Manohar, Pipaliya, Akash
Traction Voltage Level in Two-Wheeler: Considerations on E-Motor Performance2025-32-009311/03/2025
The electric power of most electric two-wheelers on the market ranges between 2 and 12 kW. For this power range, the traction voltage level is mostly between 48V and 96V. There appears to be no strong correlation between electric power and traction voltage, suggesting that the current voltage choice is rather arbitrary. This paper briefly describes the e-motor model used in this study and introduces variations of four design parameters: DC voltage, maximum phase current, e-motor active length, and the number of turns in the e-motor winding. The consequences of these variations on peak performance, continuous performance, and efficiency maps are presented. Specific cases of parameter combinations are also studied. Two e-motors designed for 48V and 96V systems will be compared, showing that size, cost, and performance (power and losses) are equivalent. Additionally, the paper discusses how increasing the maximum phase current rating of the inverter can improve e-motor power in a 48V
Albert, Laurent
Performance Investigation of Air Conditioning System in Electric Vehicle by Fault Detection and Diagnosis2025-28-035310/30/2025
The study emphasizes on detection of different faults and refrigerant leakage as well as performance investigation of automobile air conditioning system for an electric vehicle by varying various operating conditions. A refrigerant leak in an EV isn't just an inconvenience; it's a potential threat to vehicle range and usability, lifespan and health of the expensive battery pack, overall vehicle performance, passenger safety and comfort, component longevity (motor, power electronics), environmental responsibility. Due to the refrigerant leakage, the cooling system performance degrades, and components tend to fail. Because of that this study is focusing on deriving an algorithm to have an early detection of fault and leakage in the vehicle. The performance of the system is predicted for actual conditions of operation encountered by the automobile air conditioning system. The objective of the present work includes predicting the causes and effects of refrigerant leakage in AC system of
Bezbaruah, Puja, Yadav, Ankit, Pilakkattu, Deepak
1D Thermo-Fluid Model for Electric Vehicle Traction Inverter2025-01-506209/19/2025
Thermal management solutions in power electronics applications are of prime importance to meet the needs of the ever-increasing demands on higher power and torque density of the traction motor and controller. Traction inverters are essential power electronic devices that convert direct current (DC) supply from the battery pack of the vehicle to three-phase alternating current (AC) output and vice versa. Estimation of die junction temperatures and cooling system pressure drop is necessary for assessing the maximum heat load capacity of the traction inverter system and coolant pump capacity requirements. The system comprises of a power module and a water–glycol–based cooling domain with heat sink. This article proposes a 1D model for accurate predictions of junction temperatures on the SiC die, temperature rise of the cooling medium, and pressure drop across a custom heat sink fluid domain. The model is built to handle steady-state and transient conditions for varying heat loads on the
Ravindra, Vidyasagar, Prasad, Praveen, Singh, Ishan, Sureka, Sumit
Enhanced Vehicle Capability Through Innovative High Voltage Power Solutions2025-01-050609/16/2025
Increasing the mission capability of ground combat and tactical vehicles can lead to new concepts of operation that enhance safety and effectiveness of warfighters. High-temperature power electronics enabled by wide-bandgap semiconductors such as silicon carbide can provide the required power density to package new capabilities into space-constrained vehicles and provide features including silent mobility, boost acceleration, regenerative braking, adaptive cooling, and power for future protection systems and command and control (C2) on the move. An architecture using high voltage [1] would best satisfy the ever-increasing power demands to enable defense against unmanned aerial systems (UAS) and offensive directed energy (DE) systems for advanced survivability and lethality capabilities.
Eddins, R., Lambert, C., Habic, D., Haynes, A., Spina, J., Schwartz, E.
A Novel 5kW Ruggedized Integrated Hybrid Generator System (RIHGS)2025-01-050009/16/2025
This study provides an overview of the 5 kW Ruggedized Integrated Hybrid Generator System (RIHGS) developed by Enginuity Power Systems for the U.S. Army. Designed to replace three existing generator models (MEP-531A, MEP-831A, and RMP-1030A), the RIHGS features; variable-speed load following (1 to 5 kW output at 120/208V), multi-fuel capability (JP8 and Diesel #2), liquid-cooled permanent magnet motor, silicon-carbide power electronics with a bidirectional inverter, software-based controls for efficient operation, thermal management-focused enclosure design. Experimental results confirm the system maintains normal operating temperatures at full power. When using JP8 fuel, engine performance remained stable at 3000 RPM and matched Diesel #2, though fuel economy declined at lower speeds. Compared to the RMP-1030A, the RIHGS improved fuel efficiency by 4.6% on a weighted load factor. Additionally, it demonstrated fast transient load responses (<1 sec) when stepping up from 1 to 5 kW. This
Zoldak, Philip, Schimmels, Philipp, Harman, Andrew, Brooks, Ian, DeMaggio, Phillip, Rosenberger, Kelly
Evaluation of a 500kW High Temperature and High Power-Density Inverter Based on Silicon Carbide Power Module2025-01-050509/16/2025
In pursuit of increased operational duration and future high-power capabilities for U.S. military ground vehicles, the transition towards vehicle electrification has been heavily adopted. High power-density and high temperature inverters play a key role in progressing vehicle electrification adoption across the U.S. military. This paper presents the design and development of high power-density and high temperature inverter, Enercycle™ DC-1000 Inverter, using SiC MOSFET devices to enable ground vehicle electrification. The DC-1000 inverter is a bi-directional inverter with a power density of 11.4 kW/L, which is capable of operating at 600VDC and delivering 500kW continuous output power and transient output power up to 640kW. Details of mechanical design as well as experimental results of electrical and thermal performance to validate the capability of DC-1000 inverter are presented in this paper. Moreover, challenges and next steps for further improvement of design have been discussed.
Sadigh, Arash, Nolden, Randy, Yates, James Ryan, Shiroma, Iris
Instability Prediction of Onboard Power Electronic Systems in Hybrid Electric Tractors under Large Power Disturbances14-14-03-001909/11/2025
In recent years, the powertrains of agricultural tractors have been transitioning toward hybrid electric configurations, paving the way for a greener future agricultural machinery. However, stability challenges arise in hybrid electric tractors due to the relative small capacity to perform power-intensive tasks, such as plowing and harvesting. These operations demand significant power, which are supplied by the electric power take-off system. The substantial disturbances introduced by the electric power take-off system during these tasks render conventional small-signal analysis methods inadequate for ensuring system stability. In this article, we first develop a large-signal model of the onboard power electronic systems, which includes components such as the diesel engine–generator set, batteries, in-wheel motors, and electric power take-off system. By employing mixed potential theory, we conduct a thorough analysis of this model and derive a stability criterion for the onboard power
Li, Fangyuan, Li, Chenhui, Gao, Lefei, Ma, Qichao, Liu, Yanhong
Innovative Full-GaN Inverter Development for 800V/100kW Automotive Applications2025-24-013309/07/2025
In the rapidly advancing field of EV applications, the design of high-efficient inverters is one of the key factors in improving overall vehicle performance. This paper presents the design of a three-level (3-L) automotive inverter based on GaN technology, aimed at enhancing the performance and efficiency of electric vehicles (EVs). GaN components, sourced from Cambridge GaN Devices (CGD), are utilized to leverage their superior switching characteristics and efficiency. The work is supported by both simulation and experimental results, which confirm the advantages of integrating GaN components and the 3-L inverter topology. The findings demonstrate improved performance, lower losses, and enhanced overall efficiency, making this design a promising solution for the future of EV power electronics.
Battiston, Alexandre, Aghaei Hashjin, Saeid, Findlay, John, Haje Obeid, Najla, Siad, Ines
BEV Powertrain Analytics: Network Pulse Ringing – Ripple Currents - NVH Topics2025-24-013409/07/2025
The interaction of electric, electronic (E/E) and mechanical components defines the quality of a BEV’s powertrain. Component selection, their integration and calibration aim at meeting legal requirements for EMC and safety as well as competitive targets for efficiency, NVH and driving comfort. These tasks in particular need attention on electromagnetic events on the DC bus, the high-power electronics of inverters, the e-motors, and the drive shaft. Each component within this environment is defined by its electromechanical features with variabilities selected from a large set of operating parameters. Consequently, a complete powertrain and its controllers give rise to endless combinations for powertrain operation. How to understand and avoid risk laden and ineffective parameter options, how to find powertrain control parameters for safe, efficient and comfortable operation? And how to find solutions within competitive development timeframes? Particular issues include high voltage risks
Winklhofer, Ernst, Berglez, Manuel, Kiss, Gergely, Platzer, Thomas
Design of a High-Speed Pure Synchro-Reluctant Machine with Asymmetrical Poles for Automotive Applications2025-24-012909/07/2025
In this article, the authors present the various choices made to design a magnet free and directly recyclable pure synchro-reluctant (Pure-SynRel) machine with asymmetrical poles operating at a maximum speed of ~21,000 rpm dedicated to automotive. This project focused on identifying design levers and optimizing the magnetic circuit to address three well-known challenges of this topology that limit its application as an automotive traction machine. These challenges include: maximizing the power factor to reduce inverter rating and cost, minimizing sources of NVH (noise, vibration, and harshness) and torque ripples, and ultimately maximizing efficiency to bridge the performance gap with magnet-based technologies (PMaSynRel). The sizing of stator components—such as the choice of winding (concentric or distributed, full or fractional pitch, round or hairpin wire)—and rotor components (e.g., the number of pole pairs, shape, and number of barriers) are explained. Additionally, the
Applagnat-Tartet, Antoine, Milosavljevic, Misa, Delpit, Pierre
Analysis of DC Current and Voltage Ripples of Electrical Drivetrains for HV Electrical System Emulation2025-24-013509/07/2025
State-of-the-art testing of traction inverters is conducted using PHIL-based testbeds. These systems, which include a battery emulator and an e-motor emulator (EME), offer significant advantages over dynamometer testbeds in terms of test duration, reproducibility, parameterization and protection of the unit under test. In these advanced systems, the physical modeling of the AC side (e-motor) is highly detailed, accounting for factors such as iron saturation effects, current harmonics, and loss models. State-of-the-art DC side models are limited to a constant voltage and an internal resistance model, as outlined in [1], neglecting other components like additional traction inverters or DC/DC converters connected to the HV electrical system and their impact on voltage and current ripples – high-frequency oscillations in the current that can arise from power electronic systems. This research project aims to address this gap by developing an HV electrical system emulator that considers
Merath, Stefan, Winzer, Patrick, Reick, Benedikt
New 3D Chips Could Make Electronics Faster and More Energy-EfficientTBMG-5375709/01/2025
The advanced semiconductor material gallium nitride will likely be key for the next generation of high-speed communication systems and the power electronics needed for state-of-the-art data centers.
Automotive Engineering: August 202525AUTP0808/07/2025
Moving targets: How improvements to SiC, GaN power electronics will redefine EVs Smaller devices that can do the same or more efficient work than silicon can to markedly smaller EV powertrain components. Toyota's multi-pathway future on full display The automaker's showcase HQC event highlights engineering efforts to bring PHEV, EV, H2 powertrains to more people. 48V is coming, and not just for EVs While electric powertrains are driving 48V adoption, OEMs are realizing that xEV and ICE vehicles can benefit from a shift away from 12-volt architectures. Editorial Governmental nonsense Supplier Eye Delay and extend and rescope Industry vet: Rapid change required to catch up to Chinese EV makers ZF meets changing EV market with suite of improved components Factory robots see slight drop in growth, but still have momentum SAE J3400/2 update brings quicker NACS charging Audio updates you can't even hear 2026 Toyota bZ: improved, but still not a wheeeeeEV New styling, performance in a better
Moving targets: How improvements to SiC, GaN power electronics will redefine EVs25AUTP08_0108/01/2025
Smaller devices that can do the same or more efficient work than silicon can lead to markedly smaller EV powertrain components. This story starts in 2017, when the Department of Energy's U.S. DRIVE partnership laid out targets for power electronics for 2025 in a technical team roadmap: power density of 100 kW/l for a powertrain that would last either 300,000 miles or 15 years, at a cost of no more than $2.70 per kW. Progress in the intervening years led to an updated roadmap in 2024, specifying stricter 2025 targets of 150 kW/l power density at a cost of no more than $1.80 per kW, based on a 600-volt system. Along with that came more refined targets for 2030 and 2035. For 2030, the goal is an 800-volt system that produces peak power of 200 kW maintained for 30 seconds, and a power density of 200 kW/l that costs no more than $1.35 per KW. The goal for 2035 now sits at 225 kW/L for $1.20.
Ramsey, Jonathon
Modular Thermal Management Framework for Electric Drive System Development2025-01-026207/02/2025
The automotive industry is undergoing a major shift from internal combustion engines to hybrid and battery electric vehicles, which has led to significant advancements and increased complexity in drivetrain design and thermal management systems. This complexity reflects the growing need to optimize energy efficiency, extend vehicle range, and ensure system reliability in modern electric vehicles. At the Institute of Automotive Engineering, a specialized synthesis tool for drivetrain optimization is used to identify the best drivetrain configurations based on specific boundaries and requirements. Building up on this toolchain a modular and adaptable thermal management framework has been developed, addressing another critical aspect of vehicle and drive development: efficient thermal circuit layout and its impact on energy consumption and overall system reliability. The thermal framework emphasizes the dynamic interactions between key components, such as electric machines, power
Notz, Fabian, Sturm, Axel, Sander, Marcel, Kässens, Christoph, Henze, Roman
Automotive Engineering: May 202525AUTD0505/08/2025
All (robot) hands on deck BMW leverages advanced manufacturing, AI and machine learning to build the next generation of EVs - and vehicles of all powertrains. Driving down the high cost of overspray in automotive paint processes By designing automated paint systems with superior control behavior, OEMs can improve transfer efficiency and minimize overspray and its heavy costs for automotive companies. Connected: EV battery tech advancements and facility coatings selection New battery chemistries and the rise of automated guided vehicles in EV battery plants will redefine what's expected from floor and wall coatings. Editorial Watch this Supplier Eye Sourcing re-evaluation underway ICE and hybrid-electric propulsion show staying power Intel's Weast says China leaping ahead due to focus on innovation Nira Dynamics' sensor-free tire pressure tech eyes new opportunities Study shows safety top priority of potential vehicle-to-everything consumers The transformative power of large-format
Methodology for Radiated Noise Refinement of Electrified Drivetrain Systems2025-01-009805/05/2025
Electric drive units (EDU) of battery electric vehicles and electric drivetrain components of hybrid vehicles require significant development effort and planning to ensure that a refined NVH sound quality is achieved. New tools and methods are required to understand the NVH performance throughout the development process and to ensure that NVH risks can be quickly identified and mitigated within the correct EDU subsystems. This paper discusses the development of a methodology (EDSL – Electric Drive Sound Level) aimed at addressing this need. It also outlines how the EDSL process can be used to address radiated noise issues and understand the NVH performance of the various subsystems within an electrified drivetrain component. The first use of the EDSL methodology is to characterize component-level radiated noise test results and compare the different mechanical and electrical noise sources to targets. The results from this are used to guide EDU development in the appropriate areas
Pruetz, Jeffrey E., Steffens, Christoph, Fu, Tongfang, Ford, Alex
A Comprehensive Evaluation of PU Foam Sealing for EV NVH Performance2025-01-012005/05/2025
Low density polyurethane foam was first proposed as an alternative to expandable baffles and tapes for sealing vehicle body cavities towards the end of the last century. Despite several inherent advantages for cavity sealing, the high equipment cost of dispensing amongst other reasons, this technology has not spread as widely as expected. With the advent of electric vehicles, there is an increased emphasis on controlling higher frequencies from motors, inverters and other components, and polyurethane foam can be a viable solution by providing more robust sealing. Polyurethane foam sealing is already being employed in the new breed of electric vehicles, but its NVH advantages have not been fully studied or published in literature. Using an existing electric vehicle with conventional expandable baffles & tape sealing measures, a comprehensive evaluation of NVH performance using the closed-cell polyurethane foam solution was conducted. Testing included component level bench test on body
Kavarana, Farokh, Guertin, Bill
A Review on Electric Vehicle NVH Challenges and Recent Trends2025-01-004205/05/2025
Electric vehicles (EVs) present a distinct set of challenges in noise, vibration, and harshness (NVH) compared to traditional internal combustion engine (ICE) vehicles. As EVs operate with significantly reduced engine noise, other sources of noise, such as motor whine, power electronics, and road and wind noise, become more noticeable. This review paper explores the key NVH issues faced by EVs, including high-frequency tonal noise from electric motors, gear meshing, and vibrations. Additionally, it examines recent advancements and trends in NVH mitigation techniques, such as active noise control, improved material insulation, and advanced vibration isolation systems. Furthermore, this paper discusses the role of computational tools, simulation technologies, and testing methodologies in predicting and addressing NVH concerns in EVs. By providing an in-depth analysis of the challenges and the latest innovations, this review aims to contribute to the ongoing development of quieter and
Hazra, Sandip, Khan, Arkadip Amitava
Concept of an Electromechanical Brake-By-Wire System for Battery-Electric Vehicles2025-01-880404/01/2025
Brake-by-wire systems have received more and more attention in the recent years, but a close look on the available systems shows, that they have not reached full by-wire level yet. Most systems are still using hydraulic connections between main cylinder and the brake calipers on at least one axle to ensure functional safety. Mostly, this is the front axle, since the front brakes have to convert more kinetic energy during braking manoeuvers. Electromechanical actuators are currently used for rear brakes in hybrid brake-by-wire applications solely, since a loss of the front brake calipers can lead to severe conditions and control loss of the vehicle during braking. Further, the higher mass of battery electric vehicles (BEVs) leads to much higher braking forces on both axles and to increased sizes of the electromechanical calipers. This article presents a concept for a brake-by-wire system for battery electric vehicles, which features electromechanical brake actuators on all corners and a
Heydrich, Marius, Lenz, Matthias, Ivanov, Valentin, Stoev, Julian, Lecoutere, Johan
Research on Noise Optimization Control Based on the New Dead Zone Compensation in Dual Motor Hybrid System2025-01-851604/01/2025
In a three-phase voltage source inverter, in order to prevent the direct short circuit of the upper and lower tubes of the bridge arm and ensure the normal operation of the inverter, microsecond-level dead time needs to be added when the power devices are turned on and off. However, due to the dead-time effect, slight distortion may occur in the inverter within the modulation period, and this distortion will eventually lead to harmonic components in the output current after accumulation, thereby generating torque ripple. Against the above background, implementing dead-time compensation strategies is very important. To compensate for the voltage error caused by the dead-time effect, current polarity determination is required first. Then, the dead time is compensated, thereby indirectly compensating for the voltage error caused by the dead-time effect. Regarding the dead-time compensation time, without changing the hardware, this paper proposes a solution to turn off the dead-time
Jing, Junchao, Zhang, Junzhi, Zuo, Botao, Liu, Yiqiang, Yang, Tianyu, Zhu, Lulong
A Novel EV Inverter Drive System with Integrated Single Stage Buck-Boost and Sinusoidal Output Voltage2025-01-857104/01/2025
A battery electric vehicle (BEV) employs a traction inverter to control a traction motor. One popular configuration is to make a HV battery directly connected to the input of the motor inverter. As a result, the maximum motor voltage is limited by the state of charge (SOC) of the traction battery. When the battery voltage is low the maximum motor speed and power are limited. This voltage limitation can be solved by using a traditional boost converter-based inverter. However, this approach has several disadvantages. The motor winding terminals see a PWM voltage, which results in high frequency harmonics that lead to EMI, NVH and potential additional insulation stress. Also, there are PWM-induced common mode voltages that are known to produce bearing failures as well as EMI/EMC problems that are extremely difficult to eliminate. Finally, the topology is significantly more expensive due to the high number of active switching devices needed. To solve some of the limitations and issues
Ge, Baoming, Munoz, Alfredo R., Jiang, Hong
Digital Twin, A Multiphysics Numerical Tool Chain for Next Generation Electric Drive Design2025-01-862404/01/2025
Following early adoption, the BEV market has shifted towards a mass market strategy, emphasizing on crucial attributes, such as system cost reduction and range extension. System efficiency is crucial in BEV product development, where efficiency metric influenced greatly vehicle range and cost. For instance, higher iDM efficiency reduces the need for larger battery, cutting cost, or extends range with the same battery size. BorgWarner adopted Digital Twin technology to optimize Integrated Drive Module (iDM) within a vehicle ecosystem. Digital Twin comprises high-fidelity physics based numerical tool suites offering greater degree of freedom to engineers in designing, sizing, optimizing a component versus system benefit tradeoff, thus enabling most efficient product design within economic constraints. BorgWarner’s Analytical System Development (ASD) plan used as framework provides a global unified process for tool development and validation, ensuring the digital print of a real product
Bossi, Adrien, Bourniche, Eric, Leblay, Arnaud, David, Pascal, Nanjundaswamy, Harsha
Efficiency Comparison between Single-Channel and Double-Channel Operation in Dual Three-Phase PMSM2025-01-857004/01/2025
Due to the high-power density, high torque rating, low torque ripples and fault-tolerant capability, the Dual Three-Phase Permanent Magnet Synchronous Motor (DTP-PMSM) has recently emerged as a feasible alternative for automotive applications. However, it comes with its own challenge of increased losses at low torque due to the use of 6-phase inverter or two three-phase inverters. The DTP-PMSM drive model can be designed to function in two operating modes, double-channel (dual three-phase) mode with both the inverters operating, and single-channel (three-phase) with one of the two inverters shut down. This paper proposed an efficiency analysis between single channel and double channel modes in a DTP-PMSM drive. A simulation model is prepared to calculate efficiency, and the losses associated with different parts of battery fed DTP-PMSM drive system operated in both modes. Detailed loss model is simulated to represent efficiency of a battery-fed DTP-PMSM drive system. Both single
Sun, Fengyang, Pradhan, Subarni, Yang, Jingru, Nahid-Mobarakeh, Babak, Valencia Garcia, Diego Fernando, Mavalankar, Drushan, Allocco, Alessandro
Propulsion System Design of Cadillac Lyriq Electric Vehicle2025-01-856604/01/2025
The propulsion system design of GM-Cadillac’s first electric vehicle Lyriq uses an optimized drive unit comprising interior permanent magnet (IPM) motors and silicon traction inverters. The main objective behind the drive unit design was to minimize energy losses and cost while maximizing hardware consolidation, range, performance, power density, and scalability. Two IPM motors with different length and number of stator turns are designed, while their rotor design and stator-conductor profile are kept the same. A high-speed rotor is designed to achieve higher power density. AC winding effect at higher speeds is mitigated by using a bar-conductor with much smaller cross section. The rotor surface has a special notch design to minimize acoustic noise, without use of rotor or stator skew. Also, the traction inverters in the Lyriq EV are engineered with a significant emphasis on being scalable and adaptable for various vehicle architectures while considering a broad range of requirements.
Momen, Faizul, Jensen, William, He, Song, Chowdhury, Mazharul, Zahid, Ahsan, Forsyth, Alexander, Alam, Khorshed, Anwar, Mohammad, Kim, Young
A Minimalist High-Power Boost Charging Solution Integrated into Electric Drives2025-01-856004/01/2025
The driving capability and charging performance of electric vehicles (EVs) are continuously improving, with high-performance EVs increasing the voltage platform from below 500V to 800V or even 900V. To accommodate existing low-voltage public charging stations, vehicles with high-voltage platforms typically incorporate boost chargers. However, these boost chargers incur additional costs, weight, and spatial requirements. Most mature solutions add a DC-DC boost converter, which results in lower charging power and higher costs. Some new methods leverage the power switching devices and motor inductance within the electric drive motor to form a boost circuit using a three-phase current in-phase control strategy for charging. This approach requires an external inductor to reduce charging current ripple. Another method avoids the use of an external inductor by employing a two-parallel-one-series topology to minimize current ripple; however, this reduces charging power and increases the risk
Yuan, Baocheng, Ma, Yong, Xie, Xi, Liu, Shaowei, Guan, Tianyu, Ge, Kai, Zheng, Lifu, Xu, Xu
Research on the Motor Mode Control based on the Shut off Test in Dual Motor Hybrid System2025-01-857604/01/2025
In order to improve the safety and reliability of the inverter used in hybrid vehicles and reduce the risk of inverter failure, based on the functional safety ISO26262 development process and software architecture, a safe shutdown path scheme is designed in this paper. Firstly, after entering the initialization mode, on the basis of adding the inverter control signal feedback mechanism on the inverter control system, this scheme designs the control methods and specific processes of the shutdown path test and insulation detection. The shutdown path test and insulation detection designed in this scheme are implemented during the control initialization process, including designing the hardware diagnostic safety mechanism and the unique output shutdown path test method. If the shutdown path test or insulation detection fails, the risk of IGBT out of control can be avoided; the detection mechanism of this system can effectively reduce the failure rate and potential failure rate of faults
Jing, Junchao, Liu, Yiqiang, Zuo, Botao, Huang, Weishan, Dai, Zhengxing
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