EU-Project GEN1200

Current electric vehicles for the mass market operate at a voltage of 400 V. There is now a clear trend towards increasing the voltage level to 800 V, which is expected to become the standard between 2027 and 2030. Doubling the voltage level enables a significantly higher charging power of up to 350 kW and, consequently, a significant reduction in charging times. Current levels are also reduced, thereby placing less thermal stress on the system. To further strengthen the market position of future electric vehicles, research is already underway into integrated concepts exceeding 800 V, with future operating voltages expected to be in the region of 1,200 V. Such systems must be highly efficient, cost-effective, safe and sustainable.

As part of the GEN1200 project, modular and scalable 1,700 V power electronics solutions based on silicon carbide (SiC) are being developed for 1,200 V drive systems. The solutions include innovative architectures for improved charging performance that are also compatible with existing infrastructure. In addition, highly integrated, efficient electric axles are being developed for C-segment vehicles, which can be adapted to other vehicle classes and configurations. The system is optimised holistically to maximise the benefits of higher voltage levels.

All-in-one 1200 V inverter solution for fast charging

As part of the project, innovative power electronics systems operating at voltages above 800 V are being developed, combining several functions within a single component. The traction inverter will not only control the vehicle’s drive system but will also serve as an interleaved boost converter, ensuring compatibility with existing 400V and 800V DC charging infrastructures. It also incorporates the function of a 22 kW on-board AC charger. These advancements will be integrated into a post-800V electric axle that combines electrical, thermal and mechanical elements and seamlessly integrates the power electronics, the electric motor, the mechanical transmission and various auxiliary systems. Furthermore, the project enables 350 kW fast-charging capability for advanced battery systems operating at voltages above 800 V, which are equipped with 10C charging rates, integrated electronics and modular, wireless management solutions.

From component development to vehicle evaluation

All development activities are supported by the creation of digital twins of components and systems, as well as by bespoke control strategies. These include, for example, the adjustable modulation of adaptive gate drivers for post-800 V power electronics, as well as the reduction of losses in the partial-load range. Lifecycle analyses are also carried out. Innovative test methods combine traditional component and system characterisation with x-in-the-loop techniques and experimental vehicle evaluation to cover the full range of relevant aspects: efficiency, durability, electromagnetic compatibility and interference (EMC/EMI), charging performance and sustainability.

Consortium partners