Results

HighScape WP5 results

Deliverable 6.2

1.1 Overview of project

Focused on BEV architectures with distributed multiple wheel drives, and, specifically, in-wheel powertrains, HighScape will explore the feasibility of a family of highly efficient power electronics components and systems, and including integrated traction inverters, onboard chargers, DC/DC converters, and electric drives for auxiliaries and actuators. The proposed solutions will be assessed on test rigs and on two differently sized BEV prototypes.

The project will result in:

component integration with the incorporation of the WBG traction inverters within the in-wheel machines to achieve zero footprint of the electric powertrain on the sprung mass; the functional integration of the traction inverter with the on-board charger, and the incorporation of the latter and the DC/DC converters within the battery pack; and the implementation of multi-motor and fault-tolerant inverter solutions for the auxiliaries and chassis actuators;
novel solutions, including the implementation of reconfigurable winding topologies of the drive, as well as integrated and predictive thermal management at the vehicle level, with the adoption of phase changing materials within the power electronics components;
the achievement and demonstration of significantly higher levels of power density, specific power and energy efficiency for the resulting power electronics systems and related drives;
major cost reductions thanks to the dual use of parts, subsystem modularity, and model-based design to eliminate overengineering; and
increased dependability and reliability of the power electronics systems, enabled by design and intelligent predictive health monitoring algorithms.

Through HighScape, the participants will establish new knowledge and industrial leadership in key digital technologies, and, therefore, directly contribute to Europe’s Key Strategic Orientations as well as actively support the transformation towards zero tailpipe emission road mobility (2Zero).

1.2 Deliverable Objective and Results

Work package 6 is generally dealing with the development, realization, implementation and functional testing of relevant high- and low-level controls for an optimal performance on component, system and vehicle level as well. Task 6.2 targets to validate the control performance via advanced testing model-in-the-loop (MiL) testing with the simulation framework and surrogate model from Work Package 2.

Read the full deliverable here!

Deliverable 3.4

As electric vehicles (EVs) become more powerful and compact, keeping their electronic components cool is more important than ever. One of the main challenges is cooling down the SiC MOSFET, which heats up significantly during operation. If not properly managed, this heat can damage the electronics and reduce the vehicle’s lifespan.

To address this, a new cooling solution is studied: combining traditional heat sinks with Phase Change Materials (PCMs). These materials absorb a lot of heat as they melt, helping to prevent overheating during short bursts of high power, e.g. during accelerating. Once temperatures cool down, the PCM solidifies and gets ready to absorb heat again. This process is a form of thermal energy storage.

A surrogate model was developed to predict how a PCM-based cooling system behaves. This model uses a network of thermal nodes with thermal resistances and capacitances. It takes into account how heat flows through different parts of the system, including aluminium structures, PCMs, and coolant flow.

To make sure the model was accurate, a lab setup was built that mimics the conditions inside an EV. Heaters simulate the heat from the electronics, and thermocouples track how temperatures change in different parts of the system. The model’s predictions closely matched the experimental results, proving the model can reliably forecast how the system performs in real-world scenarios.

By improving the design further, for example by increasing the amount of PCM stored in the heat sink, the PCM heat sink showed even better cooling performance under more realistic power cycles. This approach allows for lighter and more efficient cooling systems, which are vital for the future of electric vehicles.

In short, this deliverable demonstrates that PCMs can provide a smart, compact, and reliable solution to managing heat in EV power electronics, and the modelling tool developed can guide the way to better and faster designs.

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Deliverable 3.3

This report, part of the Horizon Europe-funded HighScape project, presents a comprehensive study on innovative traction inverter systems for electric vehicles (EVs) based on wide bandgap (WBG) semiconductors. The focus is on dynamically reconfigurable windings and integrated on-board charging (IOC) solutions, aiming to enhance efficiency, scalability, power density, and cost-effectiveness in next-generation EV drivetrain architectures.

The core innovation centers around e-gears, which are reconfigurable winding systems that extend the operating range of electric traction machines by dynamically altering the winding topology between series and parallel configurations. Two main implementations are explored: one using mechanical relays and the other based on semiconductor tap-changer circuits.

The mechanical relay-based e-gear offers a cost-effective and efficient solution, enabling a switch between high-torque (series) and high-speed (parallel) modes. An extension of the speed range from 1000 to 2000 rpm with minimal efficiency loss (only 0.09% reduction compared to baseline), and a reconfiguration time under 35 ms, comparable to high-end automotive gearboxes were achieved.

The semiconductor-based e-gear employs a more sophisticated architecture using SiC MOSFETs and diode rectifiers. It enables faster switching (<10 ms) and avoids torque interruption during transitions. However, this comes at the cost of increased complexity and reduced efficiency (average drop of 3.46%) due to additional conduction and switching losses.

Additionally, the report investigates both single-phase and three-phase integrated on-board chargers, leveraging the same motor windings to provide bidirectional charging functionality. Multiple configurations are analyzed, including boost PFC, interleaved PFC, and hybrid topologies. The designs aim to reduce component count, improve power factor, and eliminate the need for access to the motor’s star point, making them viable for single-motor EV platforms.

Simulation and experimental results confirm the feasibility of the proposed designs, highlighting the trade-offs between system complexity, efficiency, torque capability, and reconfiguration speed. Overall, the HighScape e-gear and IOC technologies provide a promising pathway for more compact, versatile, and efficient EV drivetrain systems.

Read the full deliverable here!

Deliverable 2.4

1.1 Overview of project

The project will result in:

component integration with the incorporation of the WBG traction inverters within the in-wheel machines to achieve zero footprint of the electric powertrain on the sprung mass; the functional integration of the traction inverter with the on-board charger, and the incorporation of the latter and the DC/DC converters within the battery pack; and the implementation of multi-motor and fault-tolerant inverter solutions for the auxiliaries and chassis actuators;
novel solutions, including the implementation of reconfigurable winding topologies of the drive, as well as integrated and predictive thermal management at the vehicle level, with the adoption of phase changing materials within the power electronic components;
the achievement and demonstration of significantly higher levels of power density, specific power and energy efficiency for the resulting power electronic systems and related drives;
major cost reductions thanks to the dual use of parts, subsystem modularity, and model-based design to eliminate overengineering; and
increased dependability and reliability of the power electronics systems, enabled by design and intelligent predictive health monitoring algorithms.

1.2 Deliverable Objective and Results

Deliverable D2.4 aims to validate the role of HighScape Power Electronic (PE) solutions in enhancing Battery Electric Vehicle (BEV) performance across diverse operational scenarios. By utilizing a simulation-based framework developed collaboratively by USR and project partners, it provides actionable insights to refine HighScape solutions and align them with advancing technologies.

The simulation activities, particularly the thermal dynamics studies detailed in Section 4, successfully emulated the power loss and temperature profiles of the power electronic components when integrated into the vehicle. These insights were instrumental in the early-stage development of the vehicle thermal management system under WP5. The use of the simulation toolchain, especially in scenarios with limited access to physical components or bench test data, shows its effectiveness in addressing critical development needs.

Read the full deliverable here!

Deliverable 2.3

The Horizon Europe HighScape project will explore the feasibility of a family of highly efficient power electronics (PE) components and systems for Battery Electric Vehicles (BEVs), including integrated tractioninverters, onboard chargers (OBCs), DC-DC converters, and electric drives for auxiliaries and chassis actuators.

In the work leading to this deliverable, the HighScape component providers and developers, focusing on the adoption of Wide Bandgap (WBG) based PE devices, have been generating the detailed simulation models of the respective components and systems (i.e., traction motor and traction inverter, OBCs, DC DC converters, drives for Heating, Ventilation, and Air Conditioning (HVAC), and high voltage levelling suspension systems, and thermal systems for PE components/the whole vehicle), with a coverage of their parametrisation involving a wide range of BEV applications targeted in the project. The models enable model-based component and system design at the electrical, electronic, thermal and control levels. The components and systems models have been assembled into a vehicle simulation toolchain, for the rapid assessment of the implications of component design at the vehicle level, including considerations of thermal aspects. Due to the associated computational effort, the component models have been converted into surrogate models, such as Functional Mock-up Units (FMU) before their inclusion in the BEV simulation model. The definition, benefits and limitations of such surrogate models are discussed in the document.

Read the full deliverable here.

Deliverable 8.1

The Horizon Europe HighScape project will explore the feasibility of a family of highly efficient power electronics components and systems, and including integrated traction inverters, onboard chargers, DC/DC converters, and electric drives for auxiliaries and actuators. The HighScape deliverable D8.1 on Corporate Identity ensures a unified appearance of the project itself and the written documents as well. Moreover, it targets a better visibility and public recognition of the HighScape project and its outcomes. Accordingly, several tools have been designed for that purpose. The following sections present the process of conception and creation.

Section 2 Communication strategy
Section 3 Project Corporate Identity
Section 4 Communication Material
Section 5 Social Media
Section 6 Web presence
Section 7 E-VOLVE Cluster
Section 8 Communication plan

Further, this document shall be a common reference and guideline for further report activities within the project and the communication plan as well as public events taking place during the project.