TC48: A low cost 48V integrated drive for mild hybrid electric vehicles

The TC48 drive is a low cost, low voltage integrated motordrive solution suitable for mild hybrid electric vehicles (HEVs), off-highway traction and any application where a compact, highly torque-dense machine is required. Low voltage solutions for electric vehicles are attractive to manufacturers due to lower insulation requirements, and hence lower cost. The package is based on a 6-phase switched reluctance machine (SRM) which uses a novel stator topology and unique winding design to achieve high torque density. The power electronics converter hardware is integrated into the motor housing, giving a physically, electrically and thermally optimised solution. The complete package has been designed to be suitable for manufacturing in high volumes. This paper describes the electromagnetic design of the motor, the mechanical innovations used to physically realise this design, and the cooling system which makes the high power density possible. The integration of the power electronics and their control is also discussed. The project is the result of collaboration between Newcastle and Loughborough Universities, RDM Ltd., Productiv, Infineon, Tata Steel and Libralato