OF
The Challenge
A commercial vehicle OEM required a 300kW traction inverter for their electric truck platform. The inverter needed to achieve 25 kW/L power density while surviving harsh duty cycles including frequent regenerative braking and hill climbing. The design also required functional safety certification to ASIL-C level.
Our Approach
- Designed optimized SiC power module with double-sided cooling
- Implemented laminated bus bar assembly for low inductance
- Created custom gate driver with advanced protection features
- Designed integrated cold plate with dual-side heat extraction
- Performed FMEA and developed safety concept per ISO 26262
- Validated inverter through accelerated durability testing
Results
25 kW/L
Power Density
Target density achieved
98.5%
Peak Efficiency
At optimal operating point
ASIL-C
Safety
Functional safety certified