Advanced Functionally Integrated E-Axle for A-Segment Electric Vehicles

This paper describes the latest advancements and interim results of the EU project FITGEN, aiming at developing a functionally integrated e-axle ready for mass-market in the third generation of electric vehicles. Among the key features of the developed e-axle, the high torque density 6-phase synchronous motor is fed by an high efficiency inverter adopting the last generation of SiC power MOSFETs. A DC/DC converter between the battery and the inverter permits a regulated high voltage dc-link during traction, and provides embedded compatibility with fast charging stations having different voltage ratings up to 800V. The e-axle is completed by a single speed transmission gearbox, an innovative cooling system and an on-board charger. Dedicated algorithms are developed for the control of the motor and the DC/DC converter, to maximize the efficiency during traction exploiting a variable dc-link voltage. After an overview and description of each e-axle component, the paper also details the planned exploitation strategy of the developed technologies.