HighScape - Report on family of WBG-based integrated traction inverters with dynamically reconfigurable windings and innovative cooling solutions (D3.3)

This report, part of the Horizon Europe-funded HighScape project, presents a comprehensive study on innovative traction inverter systems for electric vehicles (EVs) based on wide bandgap (WBG) semiconductors. The focus is on dynamically reconfigurable windings and integrated on-board charging (IOC) solutions, aiming to enhance efficiency, scalability, power density, and cost-effectiveness in next-generation EV drivetrain architectures. The core innovation centers around e-gears, which are reconfigurable winding systems that extend the operating range of electric traction machines by dynamically altering the winding topology between series and parallel configurations. Two main implementations are explored: one using mechanical relays and the other based on semiconductor tap-changer circuits. The mechanical relay-based e-gear offers a cost-effective and efficient solution, enabling a switch between high-torque (series) and high-speed (parallel) modes. An extension of the speed range from 1000 to 2000 rpm with minimal efficiency loss (only 0.09% reduction compared to baseline), and a reconfiguration time under 35 ms, comparable to high-end automotive gearboxes were achieved. The semiconductor-based e-gear employs a more sophisticated architecture using SiC MOSFETs and diode rectifiers. It enables faster switching (