Integrated power pack unit

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Conventional internal combustion engine (ICE) based vehicles suffer from high emissions and high fuel consumption. Automobile customer demand for greater fuel-economy, functionality, connectivity, and convenience has increased electrification of the vehicle in both propulsion and accessory loads. Although fuel-efficient options such as hybrid electric vehicles (HEV), plug-in hybrid electric vehicles (PHEV), and all electric vehicles (EV) are available in the marketplace, their noticeably higher upfront costs related to the high-voltage (300V or more) electrified propulsion and large battery storage have affected their mass adoption. Moreover, the conventional low voltage 12V power network is reaching its limits to power the ever-increasing non-propulsion loads efficiently. To provide meaningful fuel economy improvements with marginal costs and, at the same time, cater to the increased non-propulsion electrical demands, a new class of micro-hybrid electric vehicles utilizing a 48V system is set to emerge in the near future. This proposal focuses on the heart of the 48V micro-hybrid, its integrated power pack unit (PPU). This component contains lithium battery storage to power the fuel saving ICE start/stop functionality of the 48V micro-hybrid electric vehicle as well as limited hybrid operation. The second role of the integrated PPU is to provide a stable 12V power network to energize the conventional low-voltage vehicle loads. This function is achieved by replacing the vehicle alternator with more reliable and controllable power electronics. The proposed project will design, build, test, and optimally control a prototype integrated PPU with an electric machine and power electronics. It will contain competitive technologies related to power electronics, thermal management, packaging, and battery management systems. Significant knowledge and hands-on experience will be created for both university research students and industry partners. The project outcomes will significantly benefit electrified vehicle technology leading to economical automotive manufacturing and a more sustainable transportation system.