Featured on Future Vehicles.
The automotive sector leads on the implementation of electrification technologies, with regulation driving towards sales of electric-only light vehicles by 2035, possibly sooner if legislation is amended.
The initial focus of investment by the industry has been on energy storage – specifically batteries – to meet Rules of Origin requirements and avoid tariffs. The immediate approach for Power Electronics, Machines and Drives (PEMD) technologies by larger OEMs has been to import components and subsystems for final assembly in the UK, limiting overall risk in the transition to zero emission vehicles. However, this has not stopped the development of the PEMD technologies required to deliver efficient, and increasingly cost-effective, electric vehicles. This includes the development of high voltage, high power and fast-switching power modules and more efficient electric drive units so that, in a total systems approach, the Bill of Material cost for batteries, motors and power electronics can be optimised. The opportunity for the UK PEMD community is to demonstrate capability, capacity and competitiveness with the required high levels of reliability to provide systems to meet specific performance requirements and win domestic and export business.
Power Electronics, Machines and Drives (PEMD): A key part of the puzzle
PEMD technologies are fundamental enablers for achieving a sustainable, zero emission future. Power electronics are needed to control the generation, transmission, storage and deployment of electrical energy. Electrical machines take this energy and convert it into motion.
As a significant global manufacturer, the UK must build its own solutions for these critical emerging technologies and deliver economic growth, rather than relying on overseas supply chains. The opportunities for PEMD technology suppliers go beyond the automotive sector, into all forms of transportation, but also into green energy generation and distribution and the decarbonisation of industry and the domestic heating sectors.
However, to fulfil the ambitions for EVs and be internationally competitive, the sector needs to develop and innovate; also, many companies are looking to pivot towards electrification technologies and take advantage of these emerging Net Zero based opportunities. To be successful, they need to access expertise, facilities or equipment to drive innovation. Many manufacturers also face the challenge of securing external investment to develop, scale and commercialise new technologies; to do this, they first need to test and validate their product and process capabilities.
The UK is well positioned to take advantage of the electrification opportunity: we have a robust R&D landscape, supported by world-leading universities and Research and Technology Organisations (RTOs) like the Catapults. For PEMD, the Driving the Electric Revolution Industrialisation Centres (DER-IC) network, of which both Universities and Catapults are part, plays a key role in this ecosystem. The DER-IC network has been funded by Innovate UK through the Driving the Electric Revolution programme, showing the government’s support for the PEMD sector. Power electronics, in particular, are an important component for delivering the UK’s National Semiconductor Strategy, which aims to improve supply chain resilience.
DER-IC offers development and scale-up facilities for UK manufacturers to accelerate and de-risk their electrification journeys, comprising most elements of the value chain shown.
DER-ICs provide subject matter expertise with state-of-the-art equipment and facilities for the PEMD manufacturing supply chain to innovate, commercialise and scale up operations, delivering market transformation and growth. DER-IC can support manufacturers in developing and testing prototypes at a lower risk and cost than the more challenging self-funded route. This can happen through commercial projects, where IP is fully protected, or through collaborative R&D projects, which usually have several industry partners working together to develop a supply chain capability.
Testing and de-risking investments: A collaborative effort
One such collaborative project is UK-Alumotor, showcased at the Cenex Expo 2024, by both DER-IC and WMG. Six partners, including WMG and Ricardo, collaborated to develop sustainable electric motors suitable for volume production. UK-Alumotor sought to develop preferred manufacturing processes that are suitable for the volume production of a patented motor design from the UK supply chain, with the overarching aim of developing the next generation of sustainable electric motors. The project also refined the design to meet the future requirements of its UK and international stakeholders. Meeting the requirements of international suppliers frequently leads to further testing and validation due to the many standards and certifications to comply with mandates of different markets.
The UK-Alumotor project outcomes aim to deliver a more affordable, environmentally sustainable magnet-free design which displaces the need for scarce material resources, resulting in a greener and more economical solution to support the mass adoption of electrification.
The right tools for the job
A crucial part of the testing and de-risking stage of developing new technology for EVs is having the right equipment and facilities, along with the expertise to operate them to the required levels of quality.
A new DER-IC capability, highlighted at the 2024 Cenex Expo in the session “Motoring Through – Developing a PEMD Support Ecosystem,” is the Power Electronics Reliable Manufacturing In-process Testing (PERMIT) facility at WMG. The PERMIT facility can assemble prototype power electronics assemblies such as Inverters, On-Board Chargers and DC to DC Converters. It consists of a flexible, semi-automated production line, with in-process testing and data acquisition and end-of-line test systems. It provides production line-ready instrumentation to populate a manufacturing process database, including test waveforms and serial numbers, suitable for post-processing and defect evaluation. A typical inverter assembly process consists of 100-130 process steps which can give rise to between 40-60 potential defects. PERMIT carries out tests covering electrical control, mechanical and manufacturing processes to provide data for defect analysis, manufacturing consistency and post-assembly validation. A first-use project with an industrial partner is currently in planning.
These two examples featured at Cenex Expo 2024 are the tip of the iceberg of DER-IC’s extensive facilities across the country. For more information on how DER-IC supports the development and testing of new technologies in the EV sector, please contact Jon King, DER-IC Midlands Centre Lead, at midlands@der-ic.org.uk..