The first “8-in-1” proof of concept* (PoC) for electric vehicle (EV) E-Axle systems was unveiled by Renesas Electronics. This system is said to use a single microcontroller (MCU) to operate eight functions. This proof of concept, which was developed in partnership with Nidec Corporation, combines an on-board battery charger (OBC), a motor, a gear (reduction gear), an inverter, and a DC/DC converter. To guarantee its functionality, system-level testing was also finished. 
In electric vehicles, the E-Axle is a unit that consists of an inverter, a gear, and a drive motor. The E-Axle system is touted to simplify EV design by reducing system weight and space through the integration of various functionalities.
Renesas supplied essential parts for the new 8-in-1 E-Axle system, such as semiconductors and a reference design. Based on the reference design validated by this Proof of Concept, Renesas also intends to provide turnkey semiconductor solutions for a variety of X-in-1 systems. Equipped with these technologies, developers may quickly install and assess X-in-1 systems, which speeds up the development of EVs.
The eight functions in this PoC include a motor and gear from Nidec, a Renesas inverter with 70 ~100kW output performance and a maximum efficiency of 99 percent or higher, a 1.5kW output DC/DC converter, a 6.6kW charge OBC, a power distribution unit (PDU), a battery management system (BMS), and Positive Temperature Co-efficiency (PTC) heater control for automobiles.
Renesas successfully created a new E-Axle system that can function with just one MCU and a power management IC (PMIC) to control the entire 8-in-1 system, when typically each function of an E-Axle requires a dedicated MCU and a PMIC to govern an X-in-1 system. By methodically combining these features into a single MCU, the PoC has drastically decreased the quantity of parts, price, and
Numerous Renesas products are included in this proof of concept, which has been evaluated for optimal performance. These include the 32-bit MCU RH850/U2B for automotive control, a PMIC for the MCU, an isolated gate driver RAJ2930004AGM, an IGBT module for the inverter, and power devices for the DC/DC converter and OBC.
By using these advancements, Renesas is able to offer clients complete software and system support in addition to essential components for X-in-1 solutions. Renesas is dedicated to offering complete system solutions, including as software and reference designs, to hasten the development of EVs.
Key Comments
“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. “We are committed to delivering a broad range of power management products that work together with our digital products to provide complete, ready-to-use, system-level solutions. This approach enables Renesas to help customers accelerate their development and time to market.”
“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. “Having a single ECU manage an electric powertrain control unit will help lower the weight and cost of the system, reducing the number of components.
“We were able to develop the world’s first PoC that controls an 8-in-1 system with a single MCU, and we are grateful for the Renesas team’s passion and collaboration on this project. This project made us realize the importance of developing a scalable design methodology, as the levels of X-in-1 system integration vary from segment to segment. By modifying the software configuration for multi-core MCUs, we expect to build the foundation for an X-in-1 platform that can flexibly accommodate various combinations, added Ryuji.”
At electronica 2024 in Munich, Germany, from November 12–15, Renesas will present a live demonstration of the revolutionary E-Axle design (Hall B4, Stand 179).
