This project investigates computer simulation methods for power electronic systems. Power electronic systems are essential sub-systems in key energy conversion application areas such as electric vehicle powertrains, marine propulsion, aerospace, renewable energy and power distribution. They are complex assemblies of electrical, mechanical and thermal management sub-systems and components. Optimal system designs require understanding of electrical, electromagnetic and thermal interactions between components - the way in which a component is integrated during system manufacture can have a significant effect on system performance and lifetime. Computer models that can be passed from component to system manufacturers are needed to allow effective digital system design optimisation. Existing models provided by power electronic component manufacturers are limited to circuit models which cannot account for the 3D system geometry, component placement, or manufacturing processes used. 3D CAD component models could be provided but to be useful, detailed and high-resolution models are needed which would expose IP. Complex Finite Element simulations would then be needed to evaluate these models and these simulations are extremely computationally expensive - potentially taking days to complete. Historically, models have been used to evaluate worst case electrical and thermal performance given expected operating conditions but increasingly, lifetime and reliability is of concern. Predicting worst-case electrical and thermal performance is straightforward because maximum power and ambient temperature operating points can easily be defined and simulated. Predicting lifetime and service intervals for components is more difficult as component wear-out is determined by accumulated stress and damage sustained under normal operating conditions - different conditions within the acceptable performance envelope can give drastically different service lifetimes. Wear-out also occurs over long time periods which necessitates long simulations, if the models used are not incredibly efficient then this further increases the amount of time required to run the simulations. The research undertaken will propose a new Real-Time Virtual Prototype (RTVP) model architecture for power electronic components. The RTVP models utilise reduced order modelling algorithms that allow the models to simulate over 1000 times faster than conventional Finite Element models. These models can then be coupled together and simulated very quickly (faster than real-time in certain scenarios) to allow system manufacturers to evaluate system performance, including wear-out and reliability, over extended time periods. Furthermore, the models can be configured to hide sensitive design and performance data which will enable component manufacturers to release accurate, 3D models simulation models of their components whilst protecting sensitive IP. These models can be combined to produce full digital "virtual prototypes" of system designs, eliminating the need for construction and testing of physical prototypes, leading to reduced design costs and increased system performance.

The project aims to develop a UK PEMD supply chain that will combine cost effective material supply and cold rolling of a new high strength non-magnetic steel with mass production process innovations that can deliver patented lamination designs. These laminations can then be stacked into novel rotor and stator sub-assemblies to support mass production of more efficient and more sustainable electric machines with wide-ranging application across transport, energy and industrial sectors. The project will focus on the development of material supply and cold rolling processes for cost effective supply of the new high strength non-magnetic steel. Blank forming and joining processes to combine non-magnetic steel with electrical steel will be developed using latest joining technologies. Coating of the patented laminations will use novel insulation/adhesive coating materials, to enable automation of lamination stacking for novel rotor and stator sub-assembly designs supporting mass production of more efficient and more sustainable electric machine designs. In the project the materials and process developments will be applied to the core of a unique AEM electric machine design that will be free of rare earth magnets and copper, validated with prototype motor high speed dynamometer testing. This electric machine design is currently being evaluated by leading global automakers and Tier 1's as a more sustainable electrification solution for mass produced passenger cars. Thereafter the core technologies of the project can be applied to other transport, energy and industrial sectors, providing automotive economies of scale. The partners in the project provide the basis of a 'production ready' UK supply chain with a clear 'end to end' route to market for cost effective materials supply and cold rolling processing, lamination manufacture and rotor/stator sub-assembly, and electric machine production. This project will include production costing and value chain analysis to ensure that this UK supply chain is both market attractive and sustainably profitable.

"OCTOPUS builds on the success of previous Innovate UK project APEX. **Advanced Electric Motors Research** and **The Thinking Pod innovations** will focus optimising the integrated motor and power electronics 'drive' technology and further integrating with a new transmission and thermal management system to deliver the ultimate single unit e-axle solution designed specifically to meet **Bentley Motors** performance specifications. OCTOPUS will use the world class synchrotron and high performance computing systems available from the **Science & Technology Facilities Council** to build new multi-physics modelling solutions and expertise of the **University of Nottingham** to build power electronics modelling solutions and validate them with test data generated by 'looking through' the motor while its running at its maximum operating speed of 30,000rpm. The prototype e-axle, manufactured by **Advanced Electric Machines** at their expanded manufacturing facility in Washington Tyne & Wear, will be tested to OEM Design Verification (DV) standards using the latest testing solutions and test specifications developed using both **University of Bath** and Bentley Motors vast powertrain testing experience, ensuring that it comes out of the project ready to be considered for a vehicle programme. Looking beyond the next generation, OCTOPUS will develop a suite of technologies which target the 2035 Auto Council performance targets by integrating the latest thinking in Additive Manufacturing and nano-material technologies. **Hieta Technologies** will deliver beyond state of the art thermal management and lighweighting solutions in both the motor and transmission while **Talga Resources** UK will develop materials for high performance motor windings delivering an aluminium based solution which will aim to out perform copper. By working on these technologies alongside the core e-axle design, OCTOPUS will aim to accelerate and focus their development with a view to incorporating successful elements into the testing and prototype units, laying the foundations for future design verification programmes. At the end of OCTOPUS the project team will deliver: * **An e-axle prototype** incorporating the latest magnet free motor, wide band gap power electronics and lightweight transmission systems, tested to OEM DV standards using a new test protocol proven on next generation test facilities * **A new multi-physics simulation modelling toolkit** incorporating electromagnetic, mechanical, thermal and NVH solvers operating simultaneously, validated by a never before demonstrated x-ray analysis technique * **Next generation lightweight high performance component systems**, integrating the latest material and manufacturing techniques and tested at component, sub-system and system level and with an integration route into future e-axle designs"

ElecTra brings leading edge UK research in Switched Reluctance Electric Machine design and Vehicle Control Unit development, together with world class mechanical powertrain systems design and integration expertise, and a world leading vehicle manufacturer to deliver a breakthrough in electrification of the agricultural vehicle sector. The electrified powertrain will be designed to deliver differentiated performance and flexibility without the need for both rare-earth magnets and copper windings delivering a package which is both cost effective and recyclable at its end of life The system will be widely applicable across vehicle types and markets with its ability to be easily reconfigured. Working closely with CNH International, Semikron, FD Sims and the University of Bath, Advanced Electric Machines Research, Advanced Electric Machines and SR Technology Innovations will accelerate their technologies towards market readiness while ensuring they are focused on meeting all of the requirements of an OEM design verification plan from the earliest stage of design. Building on world class design capabilities and unsurpassed experience in high volume motor manufacturing, ElecTra will enable UK based suppliers to deliver cost effective prototypes and establish supply chains which can support volume production enabling a market opportunity worth over £500M a year.

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