Renesas Electronics Corporation, a global provider of advanced semiconductor solutions, has unveiled the industry’s first 8-in-1 proof of concept (PoC) for electric vehicle (EV) E-Axle systems. Developed in partnership with Nidec Corporation, the innovative design integrates eight essential functions into a single unit controlled by a single microcontroller (MCU), significantly reducing size, cost, and complexity for EV manufacturers.
The E-Axle, a critical component in EVs, traditionally combines a drive motor, a gear, and an inverter. Renesas and Nidec’s new design takes this a step further by incorporating eight functions, including an inverter with a 70–100kW output and a maximum efficiency of 99% or higher, a 1.5kW DC/DC converter, a 6.6kW onboard charger (OBC), a power distribution unit (PDU), a battery management system (BMS), and Positive Temperature Coefficient (PTC) heater control.
Advancing Integration in E-Axle Systems
This 8-in-1 system leverages Renesas’ cutting-edge technology, including the 32-bit RH850/U2B MCU for automotive control, an associated power management IC (PMIC), the RAJ2930004AGM isolated gate driver, and an IGBT module for the inverter. Additional components include power devices for the DC/DC converter and OBC. The system has undergone rigorous testing to validate its performance, ensuring that the integration does not compromise efficiency or reliability.
By using a single MCU and PMIC to manage all eight functions, the PoC significantly reduces the number of components required, resulting in a more compact design. This reduction in componentry not only minimizes the overall cost but also enhances manufacturability and scalability for a wide range of EV applications.
Technical Highlights
The Renesas and Nidec PoC achieves:
- Integrated Efficiency: A single MCU manages all eight E-Axle functions, reducing complexity and size.
- High-Performance Inverter: Delivers 70–100kW output with a maximum efficiency exceeding 99%.
- Compact DC/DC Converter and OBC: A 1.5kW DC/DC converter and a 6.6kW OBC enhance the overall system’s energy management capabilities.
- System Versatility: Designed for flexibility, the PoC is scalable to support different X-in-1 configurations based on customer requirements.
The collaboration between Renesas and Nidec reflects a shared vision for innovation in EV technology. The design also integrates software to streamline implementation, enabling faster deployment for automakers seeking to enhance their EV platforms.
Expert Commentary
“We are thrilled to deliver the world-class 8-in-1 E-Axle solution and have successfully verified its operational performance in collaboration with Nidec,” said Chris Allexandre, Senior Vice President and General Manager of Power at Renesas. “This integrated solution underscores Renesas’ commitment to accelerating EV development by providing complete, ready-to-use systems for our customers.”
“In the rapidly changing EV market, there is a growing need for smaller and lower-cost E-Axle systems,” said Ryuji Omura, Senior Vice President, Deputy Chief Technology Officer, and Head of Nidec Semiconductor Solutions Center at Nidec. “Our collaboration with Renesas has resulted in an efficient, scalable platform capable of meeting diverse market needs.”
A Vision for Scalable Innovation
Renesas plans to expand the PoC into scalable X-in-1 platforms, accommodating various levels of integration for different EV segments. This modular approach ensures compatibility with a wide range of applications, from compact passenger vehicles to commercial EVs.
About Renesas Electronics Corporation
Renesas Electronics Corporation (TSE: 6723) is a global designer and manufacturer of semiconductor solutions. The company delivers embedded processing, analog, power, and connectivity expertise to enable billions of connected devices for automotive, industrial, and IoT applications. For more information, visit www.renesas.com.
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