Demonstrators

SCD 4.1: AI controlled redundant powertrain

ZF

BUT, TUDO, MBAG, IFAG, IFAT, IFI

Fail-operational 800V powertrain based on a three-level Active Neutral Point (ANPC) topology which can operate as a two-level inverter in case of a fault, and allows the use of 650V GaN power transistors in an 800V system. Fault detection is achieved with several hardware and software (SW) components. Driver and FPGA boards perform data acquisition for controlling transistor deadtime and short-circuit faults. An add-on board monitors for electrical arcing in the HV system. These boards interface with SW-based cognitive diagnostic system which also monitors the health-state of the electric motor and defines system reactions to prevent further damage in case of faults. The diagnostic system is executed on a new generation AURIX with a parallel processing unit (PPU), speeding up the calculations of AI systems. Further components are a new generation power management integrated circuit (PMIC) and smart rotor position sensor, both of which are capable of performing self-diagnosis. 1. Overtaking a vulnerable road user 2. Stopping in front of a crosswalk 3. Picking up a customer in a fetch-up zone A proof-of-concept for bidirectional communication approaches to the cloud (SCD1.3) is also implemented within this demonstrator. The main hardware platform for this demonstrator is a Ford Mondeo equipped with lidar, IMU and GNSS sensors, an LTE modem and a drive-by-wire kit. The used main software platform is RTMaps which enables to integrate C++ (control), Python (intelligence) and Julia (perception) modules and provides interfaces to sensors and actuators (e.g. CAN Bus). The core processing unit is a power pc with dedicated GPU next to a communication module (TTTech Razormotion).

The demonstrator has been specified based on standard series requirements for 800V automotive powertrain applications. The main sytem is to be validated on a testbench. Operation in standard mode as well as fault emulation and related system reactions to be demonstrated on a full-power testbench. Fault injection will be tested in separate smaller test setups to prevent any component damage during commissioning and testing.

Powerelectronics board (ZF) mounted on cooling system and equipped with FPGA and Gatedriver boards (TUDO):

CAD model of six-phase inverter:

GaN ANPC Phase Board: