Development of New Motor for High Power PHEV Vehicle

Ryohei Hirota･Daisuke Kitada･Shinji Oita･Hiroki Kato･Suguru Gangi･Hajime Ukaji (Toyota Motor)

CAFE and emissions regulations have been strengthened year by year, and the widespread adoption of clean vehicles with low CO2 emissions is highly anticipated. To meet the diverse needs of customers, Toyota has developed a new motor for plug-in hybrid vehicles (PHEVs). This report covers the development of the sixth-generation motor for the new RAV4, which aims for high output while achieving reduced losses, compactness, and lightweight by revising the stator structure, electromagnetic circuit, and cooling system.

Next gen EDU with innovative Electric Motor and Inverter technologies development

Jan Nowack･Daniel Butterweck･Shady Nada･Christoph Neuhaus･Michael Schroeder (FEV Europe)･Yasutaka Ikawa (FEV Japan)

The article gives an overview of the status, Innovations and targets of the EU funded Project HiVEP – High-Voltage Fast-Charging Efficient Electric Vehicle Powertrains, a post 800 Volt electric powertrain architecture for mass EV markets. The key innovations are a Modular Multi-Level-Inverter using SiC Wide-Band semiconductors, Rare-earth-free IPMSM Machine with active winding reconfiguration, integrated I-Charger, high C-rate battery with advanced BMS and ‘explainable AI' control, holistic thermal management and Digital twin-based optimization. The development targets are ultra-fast Charging times, 25% efficiency gain, 20% cost reduction and 21% range increase for same battery weight compared to current state of the art powertrains.

An Analysis Methodology for Quantifying Inverter Ringing Impact: Power Electronics and Peripherical Parasitic Effects

Xavier Genaro-Munoz･Kuntal Mandal･Gerard Lopez･Antonio Romero･Neus Castane･Javier A. Corea-Araujo (IDIADA Automotive Technology)

This paper presents a comprehensive analysis methodology for quantifying ringing phenomena in power electronics inverters, emphasizing parasitic effects from auxiliary components including housing, grounding systems, DC-link, and copper bar assemblies. The approach utilizes DPT testing coupled with VNA characterization for 1-D circuit modeling and establish accurate parasitic representations through systematic comparison between isolated modules and integrated systems. Key contributions include: (1) validated experimental-simulation workflow for ringing fingerprint characterization, (2) quantitative assessment of auxiliary component parasitic contributions, and (3) predictive capabilities for EMC behavior under real operating conditions.

Development of a Loss Measurement Method for Each Component of the Electric Powertrain under In-Vehicle Conditions

Jumpei Kobori･Nobunori Kita･Hiroshi Yamazaki･Yasuyuki Okada･Tomoko Numata (HORIBA TECHNO SERVICE, Co., Ltd)

Although loss measurement of each EV powertrain component on a motor bench is possible, calculating losses under actual operating conditions is difficult due to various vehicle factors. In this study, we developed a method to directly measure the losses of each component (converter, inverter, motor + gearbox, etc.) of EV powertrain under in‑vehicle conditions. We report the loss distribution under WLTP conditions, as well as the challenges identified for future work.