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Table of Contents
1. EXECUTIVE SUMMARY AND CONCLUSIONS
1.1. Optimisation using new devices and integration
1.2. Market Forecasts
1.3. Global value market for vehicle traction drives
1.4. Concern in Europe
2. INTRODUCTION
2.1. History of the Electric Motor and Motor Control
2.2. AC Vs DC
2.3. Direct Drive or gearbox
2.4. Comparison with a parallel market
2.5. Technologies and trends in the key components used in electric traction drives
2.5.1. The Power Module
2.5.2. Wide band gap power semiconductors SiC GaN
2.5.3. DC Bus/Snubber capacitor
2.5.4. New high temperature capacitor for EVs
2.5.5. Analog sensors
2.5.6. Position/Speed Feedback
2.5.7. Control DSP
2.5.8. Isolated Gate drive circuit
2.5.9. Switch Mode power supply
2.5.10. Power Distribution within the inverter
2.5.11. Digital Communications
2.5.12. EV AC drive frequency converter control Hungary
2.5.13. Nanotechnology for the power components
2.5.14. Meidensha advances energy management
2.5.15. Siemens innovative new e-car inverters
2.5.16. Volvo new integrated motor and battery charger
3. ANALYSIS OF 74 TRACTION MOTOR/INVERTER MANUFACTURERS
4. ANALYSIS OF INVERTER COMPONENT MANUFACTURERS
5. COMMENTS BY VEHICLE MANUFACTURERS AND LEADING SUPPLIERS
5.1. Toyota
5.2. Volkswagen
5.3. Ford
5.4. Toyota - Power Electronics
5.5. Fuji Electric
5.6. Renesas
5.7. Nissan
6. TYPES OF TRACTION MOTOR DRIVE IN SUMMARY
6.1. Mechanical Considerations
6.1.1. Shapes of motor drives
6.1.2. Size and number of motor drives
6.1.3. Drive position
6.1.4. Cooling Systems
6.2. Functional Safety and High Availability
7. MARKET FORECASTS
7.1. Inverter/Controller forecasts of numbers
7.2. Global value market for vehicle traction drives
7.3. System design
7.4. Influence of motor type on inverter design
7.5. Influence of battery voltage and motor performance requirements
7.6. Summary of Inverter component technology trends
7.6.1. Power Modules
7.6.2. Higher switching frequencies
7.6.3. Heat recovery
7.6.4. Snubber capacitors
7.6.5. Communications
7.6.6. Power distribution
7.6.7. Functional safety
8. LESSONS FROM BATTERY/EV EVENT MICHIGAN SEPTEMBER 2013
8.1. Comment from e-Car Tech Munich October 2013:
9. ON-BOARD CHARGERS AND DC-DC CONVERTERS
9.1. On-board chargers
9.2. DC-DC converters
10. BATTERY MANAGEMENT SYSTEMS BMS: A NEW ASSESSMENT
APPENDIX 1: REFERENCES AND WORKS CITED
APPENDIX 2: IDTECHEX PUBLICATIONS AND CONSULTANCY
TABLES
1.1. Number of traction inverters in electric vehicles worldwide 2012-2023 in thousands
1.2. Vehicle numbers (thousand) 2012-2023
1.3. Number of traction motors in multi-motor vehicles 2012-2023 and percentage of all vehicle traction motors rounded
1.4. Proportion of electric vehicles with more than one motor 2012-2023
1.5. Number of electric vehicles with more than one electric motor 2012-2023 in thousands and percentage of all electric vehicles rounded
1.6. Average number of motors per multi-motor vehicle 2012-2023
1.7. Proportion of electric vehicles with one motor 2012-2023
1.8. Number of electric vehicles with one electric motor ie number of motors in single-motor vehicles in thousands 2012-2023
1.9. Price of traction inverter to vehicle manufacturer in $k per vehicle 2012-2023
1.10. Traction inverter market value $million paid by vehicle manufacturer 2012-2023
2.1. Typical Electric Motor Applications
2.2. Motor types, applications and advantages
2.3. Comparison of key requirements in the industrial automation and automotive markets for inverters/controllers
3.1. Analysis of 74 traction motor/inverter manufacturers
4.1. Analysis of Inverter Component Manufacturers
7.1. Number of traction inverters in electric vehicles worldwide 2012-2023 in thousands
7.2. Vehicle numbers (thousand) 2012-2023
7.3. Number of traction motors in multi-motor vehicles 2012-2023 and percentage of all vehicle traction motors rounded
7.4. Proportion of electric vehicles with more than one motor 2012-2023
7.5. Number of electric vehicles with more than one electric motor 2012-2023 in thousands and percentage of all electric vehicles rounded
7.6. Average number of motors per multi-motor vehicle 2012-2023
7.7. Proportion of electric vehicles with one motor 2012-2023
7.8. Number of electric vehicles with one electric motor ie number of motors in single-motor vehicles in thousands 2012-2023
7.9. Price of traction inverter to vehicle manufacturer in $k per vehicle 2012-2023
7.10. Traction inverter market value $million paid by vehicle manufacturer 2012-2023
FIGURES
1.1. Typical e-powertrain components
1.2. On-going Development of Hitachi automotive inverters
1.3. Toyota Prius 2010 electronic control unit showing bed of IGBT chips
1.4. Number of traction inverters in electric vehicles worldwide 2012-2023 in thousands
1.5. Inverter market value $ million paid by vehicle manufacturer 2012-2023
1.6. The new MAN hybrid bus from Germany showing the power inverter and the use of a supercapacitor (ultracapacitor) instead of a battery, putting different demands on the power electronics
1.7. Example of modern vehicle inverters from Phoenix international, a John Deere Company as exhibited ant eCarTec Germany October 2012. The large unit bottom left is used in the MAN hybrid electric city bus which uses supercapacitors
2.1. Families of power semiconductor
2.2. Latest power semiconductors by frequency of use
2.3. Overview of traction inverter
2.4. IGBT Power module exposed
2.5. Figure of Merit for successive generations of Mitsubishi IGBT
2.6. Schematic drawing of Semikron SkiN Technology
2.7. Comparison of 2nd and 3rd generation Toyota Prius power module
2.8. Hitachi pin fin liquid cooled power modules
2.9. Hitachi IGBT Module with pin fin baseplate used on Chevrolet Volt
2.10. Double sided Cooling - Denso Lexus LS600h
2.11. Latest power semiconductors by frequency of use
2.12. Distribution of SiC device market 2010-2020
2.13. Potted film capacitor
2.14. Volumetric transition of metalized polypropylene film capacitors
2.15. HITECA capacitor for EV power electronics
2.16. LEM Hall-Effect current sensor
2.17. Contactless current sensor IC
2.18. Block Diagram of Freescale' s Qorivva MPC567xK
2.19. Analog Devices iCoupler Technology
2.20. Potted film capacitor for traction applications
2.21. Deployment of power conditioning subsystems
7.1. Number of traction inverters in electric vehicles worldwide 2012-2023 in thousands
7.2. Inverter market value $ million paid by vehicle manufacturer 2012-2023
7.3. Make-up of EV component manufacturers
7.4. Power and voltage requirement for energy storage systems
8.1. CrossChasm exhibiting planetary exploration EV
8.2. Sevcon motor controllers claimed to be exceptionally compact, rugged and reliable
8.3. Bosch promotion
8.4. Zytec 250 kW controller
8.5. Voltmaxx claims
8.6. Kolektor motor controller
8.7. Continental controller for hybrid vehicles
8.8. TM4 integrated controllers
8.9. Nidec switched reluctance motor controller
8.10. LSis 100 kW traction motor controller.
8.11. LSis motor controller for Hyundai Kia car
8.12. Other LSis motor controllers
9.1. On-board charger schematic in an electric boat
9.2. A cable-based Type 1 Level 1 charger for a small car or golf car
9.3. Examples of on-board chargers: Lear, Mission Motors (small company) and at bottom Delphi, G-Power (China), bottom right Volvo 22kW 3ph.
9.4. Chroma Level 2, power 6.6kW on-board charger
9.5. Mitsubishi MiEV on-board charger and system
9.6. NLG6 Fast Charger
9.7. Approach of BYD China for buses and cars
9.8. Volvo flexible fast charger
9.9. General charging schematic
9.10. Delphi EV converter
9.11. Multiple converter need
9.12. Prodrive flexible inverter schematic showing it coping with supercapacitor voltage changing with discharge state and the input/output of the battery and the electric motors.
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