Highly Integrated SiC EV/HEV Traction Drive

Objective:

Technical Approach:

Accomplishments:

Next Steps:

Potential Impact:

Adam Morgan, Yang Xu, Dhrubo Rahman, Wensong Yu, Douglas C. Hopkins, Iqbal Husain

• Design and fabricate a 55kW SiC Inverter for an EV motor drive

• Meet/exceed the DoE’s 2020 power density target of 13.4 kW/L• Provide hands-on experience and training for next-gen

workforce

• Functional integration: impingement cooling of power modules and inductors• PCB-based busbar solution for distributed DC-link capacitors • Low-profile, compact inverter design currently achieves power density of 12.1kW/L

PMSM

#1 module #2 module #3 module #4 module

• Use of interleaved boosted inverter topology• Boost stage and inverter stage operating at

frequencies of 35kHz and 70kHz, respectively• Passive components (DC-link capacitors, boost

inductors) value and size reduction • Multi-physics simulation driven design• Custom design, using viable processes,

enables functional integration; thus high power density and lower weight

Total 200µF/900V

• Open-loop hardware test of SiC inverter on RL-load, up to 55kW continuous

• Address initial shortcomings of first design test results• Closed-loop hardware test of SiC inverter on dynamometer• Development of a marketable SiC-based inverter platform

battery current battery current

dc link currentdc link current

• Proliferation of clean, sustainable EV traction drives into commercial and industrial sectors to fight climate change

• Establish the U.S. as a technological leader in design and manufacturing of WBG semiconductors