Production of power electronics
Power electronics is the key component of every electric drive. It forms the basis for the successful transition to e-mobility. Batteries are one thing, but only the successful use of power electronics ensures an efficient and reliable e-car. On the one hand, power electronics controls the electric drive and enables reversing, and on the other, it establishes the connection between the battery and the electric motor.
The simplest solution would be to use a commutated DC motor with brushes. This is contradicted by high maintenance requirements, low efficiency and a short service life.
Brushless DC motors are therefore used in electric vehicles. These require an inverter, usually a three-phase inverter, which supplies the motor with three-phase current that is variable in frequency and voltage. The interaction between the electric motor and the battery is handled by mini-computers. One challenge here is the constantly increasing demand for power while at the same time reducing weight.
A DC/DC converter, similar to the alternator in a vehicle with an internal combustion engine, is also required to produce the voltage for the low-voltage electrical system. The air conditioning, power steering, lighting and infotainment system are all connected to this.
Another component is the onboard charger. The traction battery needs direct current for charging, which is usually only supplied by gas pumps on the highways. Urban charging stations or the charging point at home usually only supply alternating current, which first has to be converted by the installed charging unit.
Technological progress and the constant further development of all system-relevant components require innovative production and flexible intralogistics. The manufacturing and conveyor systems must be easy to change and adapt. State-of-the-art production facilities alone are not enough for implementation; corresponding automated, modular and maximally flexible conveyor technology is needed.