TC48: A low-cost 48 V integrated drive for mild hybrid electric vehicles

Abstract

The TC48 drive is a low-cost, low-voltage integrated motor-drive solution suitable for mild hybrid electric vehicles, off-highway traction, and any application where a compact, highly torque-dense machine is required. Low-voltage solutions for electric vehicles are attractive to manufacturers due to lower insulation requirements, and hence lower cost. The package is based on a six-phase switched reluctance machine, which uses a novel stator topology and unique winding design to achieve high torque density. The power electronics converter hardware is integrated into the motor housing, giving a physically, electrically, and thermally optimised solution. The complete package has been designed to be suitable for manufacturing in high volumes. This study describes the electromagnetic design of the motor, the mechanical innovations used to physically realise this design, and the cooling system which makes the high power density possible. The integration of the power electronics and their control is also discussed. The project is the result of collaboration between Newcastle and Loughbosrough Universities, RDM Ltd., Productiv, Infineon, Tata Steel, and Libralato.

Keywords

• machine control
• power electronics
• hybrid electric vehicles
• power convertors
• torque
• motor drives
• reluctance machines
• stators
• low-cost 48 V integrated drive
• mild hybrid electric vehicles
• TC48 drive
• low-voltage integrated motor-drive solution
• torque-dense machine
• unique winding design
• high torque density
• power electronics converter hardware
• motor housing
• high power density
• insulation requirements
• off-highway traction
• six-phase switched reluctance machine
• stator topology
• electromagnetic design
• mechanical innovations
• cooling system
• Newcastle University
• Loughbosrough University
• RDM Ltd.
• Productiv
• Infineon
• Tata Steel
• Libralato
• voltage 48.0 V