Abstract

This work presents a comprehensive power path optimization model for electrical axles and drive systems, enabling multi-level simulation and analysis. At its core, the model optimizes the commutation cell by refining power module design, improving parallelization of bare dies, and enhancing three-phase inverter configurations. A key focus is Hie reduction of commutation loop stray inductance through the optimized design of busbars. DC-link capacitors, and power modules, all within a detailed 3D model.
High-fidelity 3D simulation results serve as input for double-pulse test simulations, facilitating an in-depth analysis of semiconductor overvoltages, gate-source (GS) effects, switching-induced ringing, and current symmetry across parallelized dies. As a parallel path, a dedicated 3D EMI filter model evaluates insertion loss, core dimensioning, and capacitor placement and selection, ensuring optimal placement of dimensions of the passive filter components.

Further integration includes a motor model and ground path representation derived from measurements and prior 3D simulations. The complete high-level model encompasses the frill drive system, incorporating the commutation cell. EMI filter, power semiconductors in SPICE models, and motor impedance. Through PWM-based operation simulations, the model provides insights into common-mode current flow, enabling precise assessment of power losses in EMC components and potential saturation effects in filter cores. Moreover, the common-mode current data supports further analysis of bearing currents in the axle when a suitable bearing model is included. Additionally, interactions between multiple power paths, such as the superposition of common-mode and load currents, can be evaluated.

This holistic simulation approach facilitates informed design decisions for enhanced efficiency, reliability, and EMC performance in modern electrified drivetrains.

Slide deck

Presenter Bio

Illia Manushyn is a senior power electronics engineer specializing in the design and optimization of high-performance power conversion systems. He holds a Doctor of Engineering degree in Power Electronics from the Technical University of Darmstadt, where he focused on EMI filter optimization for power electronics systems. With over 15 years of industry experience, he has led the development of SiC MOSFET-based traction inverters, DC-DC converters, and fuel cell inverters at ZF Friedrichshafen AG and Bosch GmbH. His expertise includes commutation cell optimization, EMC analysis, power module design, and multi-physics modeling. He has also supervised international teams and holds multiple patents in the field of power electronics and EMC.