Current mass-market electric vehicles operate at a voltage level of 400V. In the meantime, there is a clear trend to increase the voltage level towards 800V, which is expected to become the standard by 2027-2030. Doubling the voltage level allows for higher power charging , up to 350 kW charging, and the associated reduction of the necessary charging time. The current levels are also lowered, hence imposing less demanding thermal loads in the system. To further strengthen the market position of future EVs, ongoing investigations are already targeting integrated concepts beyond 800V, with future operating voltages expected to be in the range of 1200V. Such concepts should be highly-efficient, affordable, safe and sustainable.
In this context, GEN1200 project focuses on modular and scalable 1700V SiC-based power electronics solutions for 1200V powertrains, encompassing architectures for enhanced charging while ensuring compatibility with the existing infrastructure, and highly-efficient and highly integrated electric axles for C-segment vehicles, which can be extrapolated towards different EV configurations and classes. The system will be holistically optimized to maximally exploit the opportunities enabled by higher voltage levels.
The project will develop innovative post-800V power electronics systems that enable multiple functionalities within a single component. For example, the traction inverter will not only manage vehicle propulsion but also serve as an interleaved boost converter, ensuring compatibility with existing 400V and 800V DC charging infrastructures. Additionally, it will integrate the capabilities of a 22 kW onboard AC charger. These advancements will be incorporated into a post-800V electric axle, which combines electrical, thermal, and mechanical elements, seamlessly integrating the power electronics, electric motor, mechanical transmission, and various auxiliary systems. Furthermore, the project will enable 350 kW fast charging for advanced post-800V battery systems, which feature 10C charging rates, integrated electronics, and modular wireless management solutions.
All activities will be supported and enabled by the development of digital twins (DTs) of component and systems, as well as tailored control solutions, e.g., for the adjustable modulation of the adaptive gate drivers of the post-800V power electronics, and for reducing power losses in partial load conditions, and life cycle analysis. Innovative testing methodologies, combining classical component and system characterisation, x-in-the-loop, and experimental vehicle assessment, will cover the wide range of relevant aspects, including efficiency, durability, electromagnetic compatibility and interference (EMC/EMI), as well as charging performance and sustainability.
