Power Electronics for Electric Mobility

The growing demand for sustainable, efficient and zero-emission mobility means that a wide range of power electronic systems are needed. Highly efficient, high-performance converters are required in both mobile and stationary applications to increase vehicle range and reduce charging times. The interaction between vehicles and the power grid is becoming increasingly important because it harbors huge potential for load shifting and the temporary storage of renewable energy. Our engineers have many years of experience in developing conductive and inductive charging systems with outputs as high as 350 kW. Our extensive specialist knowledge and state-of-the-art lab infrastructure enable us to develop highly efficient and compact power electronic systems all the way through to pre-production. We work together with OEMs, their suppliers and charging infrastructure manufacturers to create innovative and bespoke solutions for power electronic systems.

Our R&D activities in the field of power electronics for e-mobility and grid integration comprise the following:

• Inductive and conductive high-performance charging infrastructure
• Highly efficient and compact converters for use in vehicles
• Innovative control algorithms for integrating power electronics into the grid
• Simulations of and studies on power electronic converters for e-mobility

Designing and dimensioning inductive charging systems for e-mobility requires a broad range of skills. In addition to assembling and commissioning inductive energy transmission systems with an output of up to 40 kW, we measure their performance using lab and field tests. Our activities in this area range from the design engineering of inductive transformers and the performance of electromagnetic observations on these components to the design and simulation of electric resonant circuits and the associated circuit topologies.

We also develop compact and highly efficient conductive charging infrastructure for stationary applications with an output of up to 350 kW, with plans for supporting even greater output in the pipeline. Taking into account device-specific standards, we design innovative power electronic systems until they are ready for pilot production.

A multitude of power electronic converters are needed to ensure that electric vehicle components can be supplied with the various types of electricity and voltage that they require. When developing the necessary power electronics, we focus on the power density, performance and cost-effectiveness.

In addition to using fast switching semiconductors to reduce the volume of passive components, we identify optimum circuit topologies and the appropriate safety systems for each application. We pay particular attention to ensuring highly efficient galvanic isolation, and are also highly familiar with the use of fluid cooling systems.

As we transform our energy system, the rotating synchronous machines that currently still play a huge role in ensuring the stability of power grids will progressively be replaced by power electronic converters. In a grid eventually dominated by converters, innovative approaches to grid control and grid integration will help to ensure this stability. Our department researches and develops control algorithms for power electronic systems that are used to maintain and form grids. We use a wide range of well-known development tools to support us in designing control systems (e.g. Mathcad, MATLAB/Simulink, Octave, Plecs). We also set up and commission the control systems on various low-level development platforms and on the power electronics we develop in-house.

Every project begins with an idea followed by the planning of a concept or feasibility study. During this process, our experts identify the suitable circuit topologies, calculate the dimensions of the main components required and use a simulation to evaluate the new system.

They also analyze, characterize and modify existing power electronic converters and systems. Our unique lab infrastructure is ideal for characterizing charging infrastructure and drive inverters.

We organize training sessions, seminars and presentations to share with industry professionals our expertise in e-mobility and the integration of power electronics into the grid.