The United States Department of Energy elaborates the compelling need for a commercialized competitively priced electric traction drive system to proliferate the acceptance of HEVs, PHEVs, and FCVs in the market. The desired end result is a technically and commercially verified integrated ETS (Electric Traction System) product design that can be manufactured and distributed through a broad network of competitive suppliers to all auto manufacturers. The objectives of this FCVT program are to develop advanced technologies for an integrated ETS capable of 55kW peak power for 18 seconds and 30kW of continuous power. Additionally, to accommodate a variety of automotive platforms the ETS design should be scalable to 120kW peak power for 18 seconds and 65kW of continuous power. The ETS (exclusive of the DC/DC Converter) is to cost no more than $660 (55kW at $12/kW) to produce in quantities of 100,000 units per year, should have a total weight less than 46kg, and have a volume less than 16 liters. The cost target for the optional Bi-Directional DC/DC Converter is $375. The goal is to achieve these targets with the use of engine coolant at a nominal temperature of 105C. The system efficiency should exceed 90% at 20% of rated torque over 10% to 100% of maximum speed. The nominal operating system voltage is to be 325V, with consideration for higher voltages. This project investigated a wide range of technologies, including ETS topologies, components, and interconnects. Each technology and its validity for automotive use were verified and then these technologies were integrated into a high temperature ETS design that would support a wide variety of applications (fuel cell, hybrids, electrics, and plug-ins). This ETS met all the DOE 2010 objectives of cost, weight, volume and efficiency, and the specific power and power density 2015 objectives. Additionally a bi-directional converter was developed that provides charging and electric power take-off which is the first step towards enabling a smart-grid application. GM under this work assessed 29 technologies
investigated 36 configurations/types power electronics and electric machines, filed 41 invention disclosures
and ensured technology compatibility with vehicle production. Besides the development of a high temperature ETS the development of industrial suppliers took place because of this project. Suppliers of industrial power electronic components are numerous, but there are few that have traction drive knowledge. This makes it difficult to achieve component reliability, durability, and cost requirements necessary of high volume automotive production. The commercialization of electric traction systems for automotive industry requires a strong diverse supplier base. Developing this supplier base is dependent on a close working relationship between the OEM and supplier so that appropriate component requirements can be developed. GM has worked closely with suppliers to develop components for electric traction systems. Components that have been the focus of this project are power modules, capacitors, heavy copper boards, current sensors, and gate drive and controller chip sets. Working with suppliers, detailed component specifications have been developed. Current, voltage, and operation environment during the vehicle drive cycle were evaluated to develop higher resolution/accurate component specifications.