Interim results of the H2020 project FITGEN: design and integration of an e-axle for the third-generation electric vehicles

The aim of the European H2020 project FITGEN is to develop a functionally integrated e-axle, demonstrated on a full electric urban vehicle platform, fit for implementation in the third-generationelectric vehicles. The e-axle features a 6-phase synchronous internal permanent magnet electric motor driven by a Silicon-Carbide inverter, coupled with a high-speed transmission and complemented by a DC/DC converter for both high voltage operation of the electric motor as well as for superfast charging. Preliminary results shows that the adoption of formed litz wire in the stator allow for a filling factor exceeding 50%, and that the design of the motor is capable of peak performance of 135 kW / 170 Nm, achieving at maximum operational speed of 22,500 rpm and a gravimetric power density of 5.2 kW/kg (i.e. above 50% compared to the 2018 industry standard). This paper presents the interim results of the project with an in-focus look at the end-user requirements, vehicle integration, development of the inverter-motor, optimisation of the cooling system group and integration of the on-board charger.