Summary

The Deliverable D3.1 aims to report the performances of the developed multi-physics models for all use cases. Within WP3, Task 3.1.1 “Development of Accurate Multi-Physics Models of System Components for Use Cases” has actively started in month 3 (M3: July 2021) and finished in month 12 (M16: April 2022) of the project. This deliverable reports the activities conducted to develop accurate multi-physics models of the power electronics (PE) components with different fidelity in each use case.

The developed models in this task represent the digital twin of the power electronic (PE) systems considering the design for modularity aspects and integration levels for the use cases:

• UC1- Electrification test systems using modular concepts and embedded power electronics:

The topologies for flexible converters to be used in electrification test systems with reduced size and new power levels are defined. Electrothermal circuit models and electromagnetic FEA models are created as part of Task 3.1.1.

• UC2-Powertrain inverters:

(a) Multidrive e-powertrain: Topology to be used as UC2-a demonstrator is defined and employed controller architectures to be used to design advanced control algorithms. This study aims at defining a single, multi-physics model template to merge different simulation needs (e.g. electrical behavior and thermal behavior) into a single and commonly used simulation platform. In this report, an overview of composing subdomains is given.

(b) Highly integrated e-powertrain: Parametric model of embedded power modules is developed, and FE simulations have been carried out by applying a passive thermal cycle to verify the model. Results of the simulations validate the qualitative modelling accuracy of the models generated through parametric macros.

• UC3-High power 48 V DC/AC inverter:

Based on the geometry and physical properties of different materials used in the power module structure, a modeling toolchain in MATLAB software has been developed.

• UC4-Multi-use DC charger:

The topology for multi-use off-board charger is defined, and multi-physics models of SiC MOSFETs, passive components and low-level controller are developed.

• UC5-On-board chargers (OBCs):

The topologies are defined, and multi-physics models of GaN-HEMTs, passive components and controllers are developed for sub-use cases listed below.

(a) Smart GaN on-board charger 400 V

(b) OBC 48 V with integrated DC/DC for auxiliaries 12 V

(c) Integrated bidirectional OBC 450 V and DC/DC (450 V – 48 V/24 V/12 V)

• UC6-Automotive DC/DC converter:

The topologies are defined, and multi-physics models of GaN-HEMT, passive components and controllers are developed by using PLECs along with MATLAB.

WP3 uses deliverable D1.1 “Specification of Use Cases”, and deliverable D1.2 “Requirements Document for Technical WP’s Based on Use Cases and Evaluation Criteria” as inputs.