ZXZC, a global leading automotive industry information service platform, has kicked off the ZXZC Awards 2022. For the Top 100 Players of China's New Automotive Supply Chain, the program will cover ten core segments, namely autonomous driving, smart cockpit, software, automotive chip, electrification, thermal management, body and chassis, interiors and exteriors, lightweight and new materials, as well as service providers.

In powertrain segment, the ZXZC Awards 2022 have attracted 33 companies with 41 technologies to apply for the Top 100 Players of China's New Automotive Supply Chain. Here are some details about them.

AAM 

Product: the solution for Light Commercial Vehicle Electrification

Description

AAM e-Beam Axle includes both 3 in 1 e-Beam axles and 2 in 1 e-Beam axles.

Unique advantages

AAM T series 2 in 1 e-Beam axles incorporate lightweight welding differential, aluminum die casting housing, coaxial gearbox and welded tube technology in order to solve the challenges of an electrified offset design including over-weight; over hung mass; packaging difficulties and negative vehicle handling impact. This e-Beam axle could offer an electrification solution for pickup trucks, vans, SUVs, MPVs and light logistics vehicles without sacrificing loading and towing capabilities. Our first e-Beam product for China T4500 offers 4500Nm torque with only 130 kg axle mass, much lighter than other competitors.

Photo credit: AAM

Application

Electric Pickup; light Commercial Vehicle

Prospect

As the electrification of passenger vehicles is gradually on track, the electrification of commercial vehicles has become a popular topic. The most intuitive and effective solutionfor the electrification of commercial vehicles is the electrification of axle. With the development of urban process, a smaller, lighter, more efficient electric drive axle is undoubtedly the mainstream trend of the market.

SES AI Corporation 

Product: SES Lithium-Metal Battery

Description

Today, all countries in the world are accelerating energy transformation, transitioning from fossil fuels to clean energy, thus enabling sustainable development. Transportation is a key area of energy transition, and batteries are the key to realizing electrification. The world's major car companies have successively announced to increase investment in EVs, driving the explosive growth of lithium-ion battery production. However, after more than 30 years of development, traditional lithium-ion batteries have gradually reached a performance bottleneck, especially the limitation of energy density greatly restricts the range of vehicles.

Photo credit: SES

In the periodic table of elements, lithium is the lightest metal element. When applied to batteries, it can not only reduce the weight of the battery, but also give it an energy density beyond lithium-ion batteries. Therefore, it is believed that lithium-metal batteries are the endgame of batteries.

SES lithium-metal battery adopts the same cathode material as the conventional lithium-ion battery, but the anode is changed from graphite to lithium, and the non-flammable high-concentration solvent-in-salt electrolyte can be used in lithium-metal batteries more safely and stably, fundamentally changing the growth of lithium dendrites, and there will no longer be a needle-like structure that easily pierces the separator. In addition, SES lithium-metal battery solution includes AI software that monitors battery health, providing early warning of battery anomalies weeks before potential accidents or even longer.

Unique advantages

SES lithium-metal battery combines the high energy density of the solid-state lithium-metal battery and the high manufacturability of the conventional lithium-ion battery.To improve energy density, there are four ways to do this: 1. Better anodes 2. Better cathodes 3. Less inactive materials 4. Pack efficiency. While most improvements in lithium-ion to date have been from 2, 3, and 4 above, there has been little improvement in energy density from the anode, which is still mostly graphite (a form of carbon). Anodes are potentially far more disruptive than the ongoing incremental innovations which continue to happen in the cathode, and other parts of the battery to improve overall efficiency. If the energy density of traditional lithium-ion batteries is 260-280Wh/Kg, lithium-metal batteries start from 400Wh/Kg.

In November 2021, SES unveiled the world's first automotive lithium-metal cell. The preliminary test data is 107 Ah, 0.982 Kg, 417Wh/kg and 935Wh/L. It has by far the largest capacity of lithium-metal cells in the world. SES is now optimizing the cells of this specification.

Moreover, SES lithium-metal battery can, to the largest extent, apply the traditional manufacturing process of lithium-ion battery in order to diminish the uncertainties that lie within.

With its leading technology in lithium-metal batteries, SES has attracted the attention of a number of major car companies. SES has signed A-sample joint development agreements with General Motors, Hyundai Motor and Honda Motor, marking the only three lithium-metal JDAs in the world today.

Application

The electrification is accelerating exceedingly, but this is only the beginning. Once the safer, higher energy-density and higher performance lithium-metal battery is commercialized, it can not only successfully facilitate the production of long range EVs, but also it can power the future of the transportation such as the eVTOL, intercontinental electric plane and electric truck etc.

Prospect

SES is preparing for mass production of lithium-metal batteries in 2025. In terms of cell technology, we are in the A-sample stage, and will gradually transit to B-samples and C-samples in the next few years. In terms of production and manufacturing, starting from the second half of 2021, SES is expanding its facility in Jiading, Shanghai. Phase 1 of the expansion was completed in March 2022, with a production capacity of 0.2GWh. Upon completion of Phase 2 in 2023, the production capacity of the facility will reach 1GWh, which is expected to be the largest lithium metal battery factory in the world.

onsemi 

Product: Automotive Traction SiC Power Module VE-Trac Direct SiC

Description

The NVXR17S90M2SPB is a Silicon Carbide (SiC) power module from the VE-Trac™ Direct SiC family of highly integrated power modules with industry-standard footprints for Hybrid and Electric Vehicle (HEV) traction inverter application. The module integrates the second generation of 900V SiC MOSFET technology from onsemi in a 6-pack configuration, with a low turn on resistance (1.7 mΩ), to achieve new levels of performance, efficiency, and quality. For assembly ease and reliability, a new generation of press-fit pins is integrated into the power module signal terminals. In addition, it also integrates an optimized pin−fin heatsink in the baseplate. To enhance reliability and thermal performance, sintering technology is applied for die attach.

Photo credit: onsemi

Unique advantages

1) 6-Pack for Cost efficient system integration

2) SiC MOSFET for high Inverter Peak Output Power, High Efficiency and reliability

3) Direct cooling with integrated Pin-fin heatsink, and sintering technology, further improving thermal performance and reliability

Application

VE-Trac Direct SiC is designed for EV/HEV traction inverter to convert battery energy into large amounts of torque and acceleration. The SiC-based power modules enable longer range, higher efficiency and faster acceleration for EVs.

Prospect

The VE-Trac offerings, including previously introduced VE-Trac Dual and VE-Trac Direct platforms, are available in silicon-based IGBT and in SiC with various voltages, and for traction inverter power ranging from 100 to 250 kW. With its standardized mechanical footprints and expanded power ratings, the VE-Trac product family is designed to effortlessly scale EV power outputs, accelerating the adoption of EV/HEVs.

BorgWarner 

Product: 800V iDM

Description

The compact 800V iDM consists of electric motor, inverter and gearbox, helping improve the range, driving performance and safety of electric vehicles.

Photo credit: BorgWarner

Unique advantages

The compact 800V iDM offers high integration and efficiency, and covers power requirements from 160kW to 300kW with peak wheel torque up to 5500Nm. The power module for the 800V SiC inverter uses BorgWarner's proven double-sided water-cooling Viper module technology, with reduced semiconductor size and increased efficiency. With the proven application of the patented Viper, higher reliability and adaptability are ensured. The high-efficiency high-voltage hairpin motor and oil cooling system design ensure the competitive performance and stable output of the electric drive system.

The current system has achieved ASIL C defined by the ISO 26262 standard and is fully compatible to be upgraded to ASIL D. The software is also cyber security functional. In terms of electric motors, the 800V High Voltage Hairpin (HVH), has a compact design with an outer diameter of 220mm and a maximum speed of over 20,000 rpm. Thanks to the scalable and innovative design, the HVH with its high-power density can achieve high power output in a compact packaging space.

Application

e-Drive system in the electric vehicle

Prospect

800 V enables to design more flexible solutions to optimize powertrain systems, providing more options, including longer mileage or smaller battery pack, super fast charging station will be smaller, lighter and cheaper cables, and more energy recovery during braking to further extend mileage.

Continental 

Product: IBS

Description

The shunt-type IBS continuously analyzes the status of conventional 12-Volt lead acid batteries and provides information on such key parameters as the state-of-charge, state-of-function (power ability) and state-of-health (aging) of the battery. The sensor is thus essential to the reliable operation of automotive start-stop systems. The IBS is mounted directly onto the battery and fits exactly into the niche around the negative terminal.

Photo credit: Continental

Unique advantages

1) Supports CO2 reduction measures

2) Helps to avoid vehicle breakdowns caused by early warning of battery breakdown

Application

Applicate for stop/start system and battery control system etc.

Prospect

IBS as a key component of Start/stop system which is main solution for CO2 reduction of fuel vehicle. It was also used for 12v battery management for new energy vehicle, Redundance battery system and steering control of ADAS also need IBS.Consistent with China strategy of carbon neutralization.

HARBIN DONGAN AUTO ENGINE CO,.LTD. (DAAE)

Product: M series range extender integration project R&D and industrialization

Photo credit: DAAE

Description

1) Develop an integrated product of range extender through reasonable mechanical electric coupling layout scheme which can adapt a variety of new energy vehicle engine space, improve fuel economy and emissions of range extended electric vehicles in range extended mode, help industries save energy and reduce emissions, improve the user's driving experience.

2) Realize the platform, lightweight, compact design concept, to meet the requirements of a variety of new energy vehicle space adaptation;

3) Combined with the operating conditions of the vehicle, complete the coupling between the engine assembly and the high-efficiency and low-fuel consumption zone of the extended range motor system, improve the efficiency of the extended range system and realize industrialization.

Unique advantages

1) Study endurance test method of range extender to realize engineering application and improve product reliability:

2) Based on the platform design concept,the whole machine has realized multiple layout forms,which meets the requirements of various vehicle space,among them ,it is the first case that the inclined model carries new energy vehicle in China.

3) The connection between the crankshaft end of the special engine for extender and the split-type extended range motor assembly is realized, which significantly reduces the axial size of the whole machine and achieves compact and lightweight.

4) Research and develop the sealing structure of the joint surface of the engine and generator for dedicated to the range extender,which makes the high voltage system of the range extender reaches the IP67 protection level.

5) The range extender test bench was developed,and the reliability and durability test methods were formulated and applied in engineering.

Application

Passenger vehicles, commercial vehicles, green logistics vehicles and so on.

Prospect

According to the automobile industry investment managment regulations issued by the National Development and Reform Commission,range-extended electric vehicle investment projects,so as to promote the development of new energy vehicles in China has been transformed from government-driven to market-driven,and most automobile enterprises have carried out the development of range-extended models,indicating a huge market potential for range-extended power.

NOK-FREUDENBERG (CHINA) 

Product: Electrically Conductive Nonwoven Grounding Component

Description

eCON – electrically conductive non-woven component is an innovative solution for bearing electrical erosion and electromagnetic interference safeguarding.

The specially treated nonwoven material can achieve good electrical conductivity. Combined with the oil seal, the integrated solution is easy to install with functions of sealing and conductivity at the same time.

Photo credit: NOK-FREUDENBERG (CHINA)

In addition, electrically conductive nonwoven can also be used exclusively as a conductive ring and adapted to different installation space with very low friction power loss and significantly extended life time.

Unique advantages

1) Can be combined with the oil seal, no extra space or redesign is needed. Easy to install and reliable with functions of sealing and conductivity at the same time.

2) Customized designs are flexible to be used as a pure grounding ring or as a combination with different sealing system for various applications such as water/oil cooled system.

3) Low friction and low power loss, maintenance free during lifetime.

4) Successful mass production in electric vehicles since 2015 with proved market performance.

Application

E-powertrain system(e-motor) shaft voltage/current reduction, bearing electro-erosion safeguarding, electromagnetic interference protection

Prospect

With the application trend of medium and high voltage e-powertrain platform, shaft voltage, bearing electro-erosion and EMI problems are more and more concerned. NOK-Freudenberg(China) innovatively developed eCON - electrically conductive nonwoven grounding component, is just the reliable, variable and high cost performance solution for the lifetime safeguarding of electrical vehicles.

Suzhou Hengmei Electron Technology Inc.

Product: Integrated Cell Management Unit

Description

1) support voltage detection

2) support temperature detection

3) support SPI & Daisy chain communication

4) support balancing (On-chip&External)

5) support cell impedance detection

6) support up to 250 cells in series cell information sampling

Photo credit: Suzhou Hengmei Electron Technology Inc.

Unique advantages

1) Cost advantage

2) Platform design

3) Thermal runaway warning

4) Shorten charging time

5) Echelon utilization of battery cells

Application

1) Cells end of line filtering equipment

2) UPS power supply

3) ESS

4) New energy vehicle battery system

Prospect

With the advancement of macro policies, the demand in the automotive industry and energy storage fields is growing rapidly, and the safety of batteries is becoming more and more important.

From a technical point of view, new energy vehicles and energy storage systems are similar in terms of electronic monitoring and battery management: both involve voltage and temperature monitoring to ensure the safe operation of the battery; both are related to balancing to ensure that each cell power is the same. In order to achieve faster charging, obtain a more accurate current state of health of the battery cells, and improve the safety of the battery cells, it is necessary to innovatively design the battery management system and BMS equipment, so that the battery system developers can understand the deep state of the battery. , optimize the use of batteries, increase the power limit of batteries, and predict safety risks early. Therefore, developers are more and more eager for the function of EIS (Electrochemical Impedance Spectroscopy, EIS, electrochemical impedance spectroscopy) measurement.

In the prior art, in order to ensure the safe operation of the battery, it cannot operate at the maximum charge and discharge parameters during charging and discharging, because the current BMS control system does not support EIS (Electrochemical Impedance Spectroscopy, referred to as EIS, electrochemical impedance spectroscopy). Therefore, it is impossible to apply the known EIS (Electrochemical Impedance Spectroscopy, EIS, electrochemical impedance spectroscopy) model to the actual algorithm when doing the algorithm, and it is impossible to accurately estimate the health state of the cell, as well as making an electrical early warning of thermal runaway.

And our product: ICMU, supports voltage detection, temperature detection and EIS measurement of battery cells, and uploads the measured data to the main control center through daisy-chain communication. According to the collected voltage, temperature and EIS data, the main control center can make up for the lack of functions of the existing BMS system.

Therefore, in the next time, the BMS system supporting the EIS function will definitely be the leader in the market industry.

KSHG 

Product: new energy vehicle high-voltage wire harness

Description

The new energy vehicle high-voltage wire harness based on automatic intelligent manufacturing meets 400V~800V whole vehicle electrical system, realizes the platform application requirements from A0 class to D class, meets the strict 3D layout requirements of high-voltage wire harness while meeting the whole vehicle electrical performance, reduces the types of high-voltage plug-ins, as well as the number of subparts of each plug-in, in order to realize the platformization of products and intelligent manufacturing.

Photo credit: KSHG

From the aspect of digital design and implementation, we can assist customers to complete the whole set of data platform development integrating design, engineering, process and manufacturing, shorten the development cost and cycle time, and establish and improve product life cycle management.

Unique advantages

Reduce labor numbers, shorten the production cycle, reduce production costs, improve product quality, single precise data traceability, and ensure the whole life cycle data management of new energy vehicle high-voltage wire harness.

Application

Adapt to the replacement of multi-species, small batch, labor-intensive production mode, especially the combination of early platform, ultra-high voltage platform development, new architecture stage normalized design and automatic intelligent manufacturing.

Prospect

Greatly improve the traditional new energy harness production capacity level, quality control level, production cost control ability, product whole life traceability and other aspects of technology, fundamentally reduce the cost of labor, manufacturing costs, breaking the traditional high-voltage harness labor-intensive industry processing system structure.

Shanghai Hydrogen Propulsion Technology Co., Ltd. (SHPT)

Product: high power density fuel cell stack platform technology for both passenger and commercial vehicles

Description:

Based on commercialization of both passenger and commercial vehicles, Shanghai Hydrogen Propulsion Technology Co. Ltd developed a brand-new fuel cell stack platform – PROME M4 – and is ready for mass production. The power density of this stack platform reaches 5.1kW/L and the peak power output of a single stack can be increased to 200kW. PROME M4 meets all the stringent technical requirements from commercial and passenger vehicles including higher power output, faster power response, longer durability, and stronger environmental versatility. In addition, the application of this M4 stack expands into non-vehicle field.

Photo credit: SHPT

Unique advantages:

1. Low Pt-loading, high performance, long durability MEA design and mass production technology

The team developed a comprehensive simulation model to analyze the performance and predict the durability of MEA by bridging the physical-chemical relations between raw material properties, manufacturing process of catalyst ink, catalyst layer structure and MEA performance. Also, the team built up the testing, evaluation and failure analysis capability of all important raw materials, catalyst ink, catalyst structure, membrane-electrode-assembly part. Thanks to the adoption of the ultra-thin PFSA membrane and improved water maintenance method, the MEA has self-water-balance function that enables its operating range cover extremely high temperature, low humidification, and ensures longer durability under such severe conditions. The new generation MEA has the power density of 1.3W/cm2, pt-loading of 0.27gPt/kW and 15000hr durability (comparing with 1W/cm2, 0.3gPt/kW for previous generation).

2. High performance, long durability bi-polar plate design

The team adopt a super-narrowed wiggle flow field design (repeating distance ≤1.35mm) with local optimization structure. For durability, the team developed coating design methodology, acceleration testing condition. Based on the test results, the operating voltage window is established for the bipolar plate. In combined with stack operating condition and control strategy optimization, the durability of coating is greater than 15000hrs.

3. High power density, strong reliability stack integration technology

1) Performance design methodology: developed multiple numerical tools specifically for fuel cell product design, including 1+1 dimension simulation tool, 3 dimensional full scale multi-phases model, fluid dynamic model, solid mechanics model etc. With all the tools being utilized, the team is able to solve several scientific and engineering problems such as the precise definition of the product specification, simulation of the “gas-water-heat-electricity” multi-physical coupled process, calculation and detection of the stack assembly force. As a result, the PROME M4 stack shows the obvious characters such as high performance without cathode humidification, low voltage variation and long lifetime. M4 Stack has 34% higher volumetric power density and 50% longer lifetime, comparing with previous generation.

2) Structural design methodology: invented high integrated stack enclosure structure with both positioning and limiting function; developed current collector-insulator-endplate combined structure; developed stack compress force compensation technology. With these innovated designs, the M4 stack meets all customer requirements: SAE J2380, IP67, GB/T2423.17, GB38031, GB/T33978.

Application:

The fuel cell stack technology platform for commercial and passenger vehicles can solve the technical problems from both sources, by increasing the volumetric power density and durability at the same time.

1) For vehicle application: based on the technology developed from the platform, the power density of the stack has increased to 5.1kW/L. The M4L stack based FCS which has peak power of 90kW, can meet the passenger vehicle application requirement. In the meantime, the 200kW M4H stack developed from the platform meets the commercial vehicle specifications, which typically require 150kW system power output and 200kW stack power output. The in-situ durability test of the stack and system has reached 15,000 hrs, which meets the requirement of commercial vehicle with all different tonnage levels.

2) For non-vehicle application: there are a few fuel cell exhibition programs on cargo, distributed power generation and emergency power supply system, etc. The technology from the platform covers all the application scenarios above and the fuel cell product will have very high potential in there application areas.

Prospect:

As a type of clean energy, hydrogen is a key part in realizing the “Carbon Peaking and Carbon Neutrality” goals. Fuel cell vehicle is becoming a complement of pure electric vehicle because of its outstanding performance and is an important path of new energy vehicle development.  As an efficient energy conversion device, fuel cell is the core of fuel cell vehicle and hydrogen industry development. The technology developed by SHPT can be benchmarked with the global leadership and has realized mass production with automotive standard. Based on 5 year lifecycle and thousand per year sale volume, it can create over 10 billion worth of supply chain. Hydrogen industry is showing good development momentum and has very broad future applications.

Joyson Safety Systems 

Product: Pyro Battery Disconnect

Description:

Pyro Battery Disconnect is trigger by vehicle Airbag ECU when vehicle system sense abnormal status.

Photo credit: Joyson Safety Systems

Unique advantage:

JSS Pyro Battery Disconnect can satisfy 460V and 12kA high voltage high ampere requirement; JSS Pyro Battery Disconnect can cut the circuit in 10 milliseconds.  Awarding Class 9 dangerous goods certification reduce logistical cost.

Application:

E-car fire and shock hazards; accident is happened when E-car running speed more than 60 km/pre hour

Prospect:

Accompany E-car market grow, and Chinese vehicle industry pay more attention on vehicle safety, we trust Pyro Battery disconnect has a great future.

Landai Technology 

Product: balance box assembly

Description:

The role of a balanced shaft is to use eccentric mass blocks to offset the engine first or second -order vibration caused by the piston connecting mechanism reciprocating motion when rotating. The dual-balanced shaft balance box assembly lays out two balance shafts with the center line of the cylinder in symmetrical placement. The two shaft rotates in opposite direction. The speed is twice of the engine speed, which is used to balance the second stage reciprocating inertial force of the engine.

Photo credit: Landai Technology

The problem of this design is the gear parts of the engine crankshaft transmission, due to periodic changes of sequential ignition and the insufficient of shaft rigidity lead to big torsional vibration, bringing a large partial instantaneous vibration acceleration and severe impact of gear meshing. The Balance box assy. easily creates severe gear knocking problem because of the unstable input of power. Although the vibration problem brought by the second stage reciprocating inertial force is solved, the gear knocking problem has greatly affected the NVH effect of the engine  which causing decline of the vehicle comfort.

Generally, the anti-backlash gear can effectively solve the problem of knocking and screaming. The design steps of the anti-backlash gear includes the main and the auxiliary gear parameter design and the MASTA modification simulation, the C spring rigidity and Torque setting, the reasonable design of the shaft and shell backlash, the shell CAE mode analysis and structural optimization and so on.

After design finalization, it is necessary to be manufactured by precision gear processing, gear grinding and trimming, Fourier detection of gear profile and gear lead, and dust -proof environment assembly can finally guarantee the balance box product quality.

Unique advantages:

Landai Company started to develop the balance box assembly of dual -balanced shaft in 2017, breaking the technical blockade of foreign manufacturers, realizing the first domestic balance box product with fully independent intellectual property rights and forming a set of complete balance box assembly system from research and development, manufacturing, assembly, testing and testing processes. At present, we occupies the first rank of home-made balance box market share.

Application:

Suitable for various types of engines that need to reduce the vibration brought by the second stage reciprocating inertial force.

Prospect:

Fuel engine, new energy DHT model.

Marelli

Product: vehicle dynamic control module

Description:

Marelli VDCM integrates powertrain control, chassis control, hybrid energy management, thermal management and some functions related to autonomous driving.

Photo credit: Marelli

Unqiue advantages:

1) Dual TC397 High performance MCU architecture， ANSII-D standards qualified

2) Fuel economy

3) Electrification

4) Vehicle dynamics

5) Comfort

6) Safety

7) Vehicle dynamic customization

Application:

It is suitable for conventional gasoline powered vehicles, hybrid vehicles (HEV), plug-in hybrid vehicles (PHEV), especially high-end vehicles and high-performance road sports vehicles.

Prospect:

The product has been mass-produced and can be widely used in powertrain control and chassis control for various hybrid vehicles and high-end, high-performance sports vehicles in the future.

Product：very high-pressure fuel system

Description:

This is the world first in mass production Gasoline Direct Injection system which can reach 1000bar working pressure. Very high-pressure gasoline direct injection (GDI) can enable high efficiency and clean combustion while overcoming standard GDI drawbacks such as knocking and soot and improve the engine thermal efficiency. it is the must technical roadmap in order to meet the future E7/C7 emission standard, reduce fuel consumption and carbon emission. Marelli created a complete system consist of a pump, fuel rail, injector, and an electronic control unit (ECU) with software. This system has won the 2021 PACE award.

Photo credit: Marelli

Unique advantages:

1) World first in mass production GDI system reaching 1000bar working pressure

2) High efficiency and clean combustion, significant reduction of emissions

3) Reduction of engine knock, improvement of thermal efficiency, devoted to achieving carbon neutrality

4) Effective solution to improve substantially the efficiency of ICE, that can still be an important alternative in the evolution of mobility

Application:

It can be used on various Gasoline Direct Injection engine application, including hybrid, Plug-in Hybrid, it can reduce significantly the emission (especially the particulates) , inhibit the knocking and improve the engine thermal efficiency, this is particular sensible for hybrid applications.

Prospect:

Especially used for high thermal efficiency engine, it can also work with other engine technologies (e.g. super lean combustion, active pre-chamber technology), to further improve engine thermal efficiency up to 50%.

Product: 800V electric motor

Description:

High torque and power density 800V electric motors specifically designed and tested for new 800V vehicles generation.

Photo credit: Marelli

Unique advantages:

1) Different mature designs supported by consolidated mass production that ensure stable high-quality delivery.

2) Platform products reach maximum power 350kW and maximum torque 600Nm which meet the diversification needs of customers.

3) High efficiency of the products make a significant contribution to the weight and space of the vehicle.

4) Meet insulation class C (over 220°C) with advantage insulation material which maximize the continuous working duration of the motor.

5) 97% maximum efficiency and the high proportion of high efficiency area maximize vehicle mileage.

Application:

Provide power for racing vehicles such as F1 and FE, high-performance sports cars, passenger cars and commercial vehicles. Already successfully applied on some high performance BEV.

Prospect:

The advantage of 800V technology is to shorten the charging time, to shortest the charging time on the highway specially. Marelli is committed to widely applying 800V or higher voltage motor system to all kinds of passenger cars and commercial vehicles, optimizing electromagnetic design and mechanical design to meet the increasing demand of power density and torque density.

Tsingshan 

Product: EDS PEF20A

Description:

PEF20A is a high-voltage asynchronous EDS. It has a split structure,integrating a motor, a reducer and a inverter. Its output torque reaches 3000N.m, which can meet various cars' auxiliary drive, such as sedan, SUV, MPV and so on.

Photo credit: Tsingshan

Unique advantages:

low cost, high efficiency, high energy conversion, quiet and other characteristics.

Application:

Auxiliary drive for sedan, SUV, MPV, etc.

Prospect:

Auxiliary drive for all FWD models of Changan SDA platform, as well as Chery and other market . And the volume will reach 2 million sets.

Sensata Technologies 

Product: battery current sensor

Description:

Realize battery current sensing with Shunt technology to realize

1) High accuracy and linearity

2) Can measure low currents

3) High bandwidth

4) Repeatable/Defined over-current behavior

5) No magnetic hysteresis effects

6) Low power consumption and temperature increasement

Photo credit: Sensata Technologies

Unqiue advantages

With innovative circuit design, Sensata BCS could realize:

1) Wide range: from 1mA to 1500A

2) resistance lower than18μΩ

3) Best-in-Class Error Performance: FS ±0.5%rdg

Application:

Battery Pack / BDU

Prospect:

1) Satisfy ASIL-D

2) Realize SOC measurement

3) Compatible with OCD

Product: insulation monitoring devices

Description:

Sensata SIM series is a kind of active high voltage isolation monitoring device for EV/HEVs capable of operating correctly even when the battery is active, and experiencing large voltage variations, no variations, or even if the battery is not connected. The Sensata SIM product continuously monitors the isolation resistance between a vehicle’s IT (Isolated Terra) power system and chassis for deterioration of isolation and potentially dangerous levels of leakage current. The module detects not only leakages but also capacitively stored energy that could be harmful to human operators.

Photo credit: Sensata Technologies

Unique advantage:

1) Could realize active insulation monitoring

2) ±5% error

3) Response time < 5s

4) Reports isolation resistance in Ω/V

5) Also reports capacitively stored energy

6) Best in class performance during voltage transients

7) Monitor isolation resistance before battery connected

Application:

1) OBC main circuit

2) Charging Pile

Prospect:

With development of 800V system and wide usage of high-speed recharge, the request on insulation monitoring will be harsher in the future. Thus, the active IMD will be widely used by vehicle and charging stations.

Shanghai Edrive Co.,Ltd. 

Product: GaN-based motor controller

Description:

The GEN-Ⅲ wide band gap semiconductor-GaN is used as the power unit device of the motor controller instead of the traditional IGBT. For the power unit, GaN devices with top cooling (special CCPAK package) were used, and four parallel devices are adopted. The highest working voltage can up to 420VDC, meanwhile the peak power is 35kW.

Photo credit: Shanghai Edrive Co.,Ltd.

Unique advantages:

Refer to the figures shown as below, the switch speed of GaN device is 10 times of IGBT. The switch power loss is much less than traditional power device thanks to its fast switch speed, around tenth of that.

Compared with the traditional IGBT scheme, the efficiency of GaN controller is significantly improved under the same test conditions, with the highest efficiency up to 99.34%, especially for the efficiency improvement under rated condition, so the vehicle NEDC efficiency will also be significantly improved.

This scheme uses traditional silicon procedure (GaN-ON-SI) devices. Compared with SiC devices, its manufacturing process is relatively simple.

Application:

Motor controller、DCDC、OBC, etc.

Prospect:

With the increasing demand for higher efficiency and higher power density of EV’s motor controller, the development and application of WBG semiconductor devices have become the focus. The characteristics of high frequency and high efficiency of GaN devices can well meet the needs of practical applications, and it is believed that GaN devices can also occupy a place in the future EV powertrain application field.

Webasto

Product: high performance charging system solution Webasto Next

Description:

As an innovative system partner to auto manufacturers, Webasto charging solutions offers a full range of charging solutions suitable for 7kW / 11kW / 22kW AC and 20KW DC. The Webasto Next charging unit adopts excellent structure design and is developed and produced in accordance with the vehicle classification process system, ensuring the high safety and reliability of the product. Its unique high altitude, high protection, high anti-collision grade and safety technology escort the charging of new energy vehicles.

Unique advantages:

Wide adaptation, easy to use, super protection (highest anti-collision grade, lightning protection, temperature monitoring, relay adhesion detection), security cloud platform, smart interconnectivity.

Photo credit: Webasto

Technical concepts:

1) Based on the proven design evolution of current wall-mounted products and in compliance with relevant Chinese regulatory standards

2) Ensure electric clearance and creepage at high voltage at high altitude of 4000m

3) Higher than the industry level of system collision resistance and highly reliable

4) Global platform design and leading technology level. It is in accordance with ISO 26262 functional safety level ASIL B, and its network security design can protect user information security.

5) Leading manufacturing process APQP VDE (German certification), filling the gap of cross-border products in the industrial and OEM fields

6) High relay certification

Application:

OEMs equipped with the standard chargers, residential areas, super markets, offices, vehicle operation companies

Prospect:

In order to achieve the goal of double carbon, with the rapid growth of new energy charging infrastructure, charging products with high reliability, high safety, high quality and performance will be the main demand of OEMs and customers.

Eaton 

Product: Breaktor™

Description:

The analysis of conventional circuit protection considerations concludes that there is clearly a need for a new protection solution. The development trends in the voltage and power levels underline the increasing complexity to protect against the electrical fault scenarios. The solution needs to

1）offer a fully coordinated circuit protection and switching solution,

2）actively interrupt but also passively trigger in case of power loss,

3）improve functional safety of critical protection systems,

4）deliver improved component serviceability and/or resettability.

Photo credit: Eaton

Eaton developed a solution considering the criteria above. Breaktor™ circuit protection combines two key components into one: the circuit breaker and the relay, and thereby is capable of handling the full protection range from overloads to short-circuits as well as the switching functionality in normal operation.

Unique advantages:

In normal switching operation, the driver coil closes the contacts powered by a 12V supply to switch the device on and falls back into off-mode when the supply voltage drops off.

Breaktor constantly monitors the current levels with the onboard current sensor and shuts-off the power to the driver coil once an overload condition is detected. The trigger overcurrent level is adjustable.

For short-circuit situations, Breaktor detects the condition in less than 1ms and disconnects the driver coil. This high-speed deactivation helps to prevent contact welding. Furthermore, Breaktor utilizes the effect of electrodynamically contact levitation positively to limit the current through to the system. This effect is threatening in the case of contactor and fuse combinations, since the levitation of conventional contactors can disrupt the fuse reaction to the fault.

In any fault case, after the respective safety checks, Breaktor can be re-activated.

Breaktor not only replaces protection and switching components, but also eliminates high voltage busbars and auxiliary voltage harnesses in the system due to the reduced number of overall components and connections within the system protection architecture. The integration of Breaktor therefore poses advantages form a system perspective with regards to optimized cost, power density, and safety assurance.

Breaktor advanced circuit protection is the perfect combination by covering the full protection range for overloads and short-circuit scenarios and can actively interrupt but also passively trigger in case of power losses. It improves the functional safety of the protection system and adds resettability as a key feature into the value proposition of the protection system.

Application:

Circuit Protection for electric vehicles

Prospect:

The Breaktor circuit protection solution offers fast, safe and reliable protection for high-power battery and inverter systems. New EVs have increased power levels, which drives the need for advanced circuit protection for these high-voltage systems.

Infineon 

Product: HybridPACK™ Drive package Based IGBT/SiC Compatible Design Solution

Description

Infineon HybridPACK™ Drive(HPD) package which had been accepted as standard in semiconductor industry. HPD family have IGBT based and SiC based module products, can be used for 400V/800V battery platform and support to output >200kW applications. HPD family has variant products and compatible package, can support cost-effective strategy in term of platform development.

Photo credit: Infineon

Unique advantages

1) IGBT/SiC compatible design.

2) Module family with wide range of performance versions to support different inverter platforms from customer side.

3) Cover broadest voltage/current and power range.

4) Support high power application due to direct cooling structure.

5) Ease of manufacturability: PressFIT pins.

Application

EV/HEV/PHEV

Prospect

HybridPACK™ Drive package will integrate Infineon next generation SiC chip and IGBT(EDT3) chip, the development schedule can be observed on the HPD family roadmap for the future, we believe that HybridPACK™ Drive family products will support long term development strategy for xEV market.

CRRC Times Electric 

Product: key technology of high voltage electric drive system based on SiC device

Description:

The technology recommended in this report is based on the electrical integration and mechanical structure integration of the electric driving system. Performances of the above aspects of the electric driving unit products were comprehensively considered and improved. Key technical problems in the promotion process and mass production application were solved as well.

Photo credit: CRRC Times Electric 

Unique advantages:

The technologies recommended in this report have been deeply studied and researched in methodology level regarding the challenge of EDS EMC performance, EM insulation performance and EDS NVH performance. These technologies are able to enhance the Top-to-Bottom design ability, decrease the time and number of iterations of design-verification- optimization process, shorten the development duration and improve the performance parameters effectively at the same time. It can reach and even beyond the level of what 400V electric drive system has achieved.

1) Filter design technology for SiC electrical driving product. We established a high frequency interference simulation model including SiC power device, gate driver, main circuit topology and motor. The EMI interference mechanism and transmission path caused by high switching SiC devices are analyzed. And the interference characteristics are extracted. High voltage EMI filter is designed to achieve better noise suppression effect. Thus EMC performance of electric driving system can reach Class5 grade.

2) Design and application technology of motor insulation system based on SiC high voltage and oil cooling application scenarios. The aging mechanism of SiC high-voltage oil-cooled insulation system is revealed through the compatibility research on the PD and breakdown voltage strength of the insulating paper, the magnet wire and material of the insulation system, combined with the reaction mechanism of polymer groups-oil-water molecules under high temperature and high pressure , and we created the insulation life model and life evaluation method as well as the compatibility evaluation standard of insulation material and oil. The motor insulation system developed based on this achievement not only breaks through the maximum voltage limit of the IEC type I insulation winding structure, but also greatly improves the oil withstand reliability of the insulation system.

3) Vibration noise control technology for motor-inverter-gearbox integrated electric driving system in complicated environment. In order to adapt to the dynamic and uncertainty of the external environment, such as high motor speed and high temperature environment, we studied the coupling mechanism of the vibration noise and transmission path under the operation of high voltage SiC driving system. And we  established vibration noise analysis model including motor current harmonics, torque ripple and motor vibration. A whole integrated vibration noise analysis method of electric drive system was built. Through the improved pulse width modulation technology, the NVH performance of the electric driving system was improved under all working conditions. More than 10% higher NVH performance was achieved compared with the existing 400V system.

Application:

This technology can be widely applied to SiC used high-voltage driving unit platform, especially in the application of SiC inverter with oil-cooling motor.

Prospect:

The technology recommended in this report is in line with current trend of higher voltage for new energy passenger car electrical architecture, provides solutions to the problems of EMC, insulation and NVH of SiC used high-voltage driving system.the methodology studied by these technology can also be transplant to 400V electric driving system, so the technology has good application prospects in the process of 400V voltage platform transferring to 800V voltage platform as well. 

ruhlamat Huarui 

Product: NEV Flat-wire motor stator automation assembly & testing line

Description:

The whole line includes many core technologies., such as Bending, Winding, Pin-inserting, Spreading, Twisting, Welding, AIO testing, Trickling, Coating, Electric performance test etc.

Photo credit: ruhlamat Huarui

The production line integrates many technologies, such as robot system, laser welding, RFID, Machine Vision detection, multi-robot controlling and synergizing etc. Adopt the innovative flexible automatic solution, the whole production line is intelligent with automatic ordering, automatic feeding, automatic assembly and detection, and automatic packaging etc.

Unique advantages:

1) Automatic production line

2) Enable to produce the most complex Hair-pin stator production ( 8 layers, 800V oil-cooled, with overline layer + I-pin, Busbar leads 3-phases line from the corolla-ends)

3) CT :122s

4) Modular designing

5) Integrate the Digitalization solution with MES and ERP system, the whole automatic production line can be digitalized managed and controlled by embedded Smart Manufacturing system. Re-define the traditional production mode of the stator, to solve many production problems, such as too many processes, high labor costs, low work efficiency, difficult to guarantee consistent product quality. While to achieve smart production process for flat-wire stator, ensure product quality consistently, reduce labor costs, increase efficiency, reduce TOC.

Application:

NEV flat-wire stator mass production

Prospect:

The major OEMers are intent to switch to flat-wire motor. But the penetration rate and installed capacity of hairpin stators are very low currently because of some limitation elements, such as automatic production process, cost, lead-time etc. Along with the flat-wire stator automatic production line to be launched in China market, the market demand of flat-wire stator will increase considerably in couple of years, the market size will getting bigger, which is enable the flat-wire stator manufactures speed up their mass production process, and to accelerate the penetration rate of flat-wire motor.