Insight Hub Category: R&D

The PERTE VEC-CAPITAL project has been funded by the European Union – Next Generation EU. Its goal is the technological advancement and industrial development of the bus value chain and associated infrastructure, driving the decarbonization of the transport sector through zero-emission solutions.

Over the past three years, the project has provided a unique opportunity to collaborate with leading Spanish companies in the electric bus sector. Together with key industry partners, we have worked on developing next-generation powertrain technology for heavy-duty electric mobility.

Decarbonizing Urban and Collective Transport in Spain

Led by the Irizar Group, this ambitious initiative focuses on the decarbonization of urban transport and the promotion of sustainable mobility solutions. The project involves the development of 100% electric buses and industrial vehicles for urban use, while also exploring the role of hydrogen fuel technologies as a complementary solution for collective mobility.

By addressing multiple zero-emission technologies, PERTE VEC-CAPITAL strengthens Spain’s leadership in the transition toward a sustainable transport ecosystem.

NX’s Innovation: High-Performance Inverter for Heavy-Duty Electric Mobility

Within the consortium, NX has contributed by developing a cutting-edge inverter designed for heavy-duty applications, capable of delivering up to 350kW.

Key achievements of NX’s inverter technology:

• Exceptional power density enabling more compact and efficient designs
• High efficiency for optimized performance in demanding applications
• Advanced safety-critical functionalities compliant with ISO 26262 standards
• Cybersecurity features aligned with ISO 21434 regulations

This development represents a significant step forward in enabling zero-emission vehicles that meet the highest requirements for safety, reliability, and performance in the mobility sector.

A Strategic Collaboration of 21 Leading Companies

The success of the PERTE VEC-CAPITAL project has been possible thanks to the collaboration of 21 companies working together to strengthen the value chain of electric buses and charging infrastructure.

This initiative has received funding from the Spanish Ministry of Industry and Tourism, under the Strategic Projects for the Recovery and Economic Transformation (PERTE), and from the European Union’s Recovery and Resilience Mechanism (Next Generation EU).

Project partners include:

Irizar, Irizar E-Mobility, Jema Energy, Masats, Datik Información Inteligente, Internacional Hispacold, Iberdrola, Fundación Cidetec, Edai Technical Unit, Ekide, Sisteplant, Construcciones Mecánicas Jose Lazpiur, Cayata, EPowerlabs, Polirrós, Falcon Electrónica, Baleike, Mendiaraiz, Lis Data Solutions, Ingurumenaren Kideak Ingeniería, and Owasys Advanced Wireless Devices.

Driving the Future of Zero-Emission Public Transport

The outcomes of the PERTE VEC-CAPITAL project not only reinforce Spain’s leadership in sustainable mobility and innovation but also demonstrate the value of collaborative research and industrial development in accelerating the transition to zero-emission public transport.

Looking ahead, the consortium’s achievements will serve as a foundation for scalable, reliable, and sustainable transport solutions that meet the evolving needs of urban environments across Europe and beyond.

 

 

Integrating electric motors with inverters is a well-known engineering challenge, particularly when components are not designed as a unified system. This is often the case in applications where off-the-shelf motor controllers are used, requiring maximum flexibility to ensure compatibility and performance.

One particularly demanding scenario arises in high-power applications, such as electric buses and trucks, where a single motor may be driven by multiple motor controllers. Coordinating these inverters efficiently is key to ensuring reliable and synchronized system behavior.

 

 

Multiple motor controllers operating on a single electric motor

At NX, we have developed a practical and robust solution: a primary-secondary motor controller configuration that allows multiple inverters to operate on a single electric motor.

• The primary motor controller  supplies the position sensor, executes the main control algorithm (speed/torque), and transmits synchronization signals.
• The secondary motor controller receives required information and operates in coordination with the primary unit, ensuring optimal performance and precise torque or speed control.

This approach significantly simplifies system architecture while maintaining high performance. It is ideal for complex and high-power electric motors.

By allowing primary-secondary unit mode, NX delivers greater flexibility and scalability in power electronics applications. It is a valuable solution in scenarios where high power and high current demand smarter and coordinated motor controller strategies.

The diagram below aims to depict a setup for a double winding or multiphase electric motor driven by 2 NX’s controllers. Here the 3 synchronization levels are shown: position sensor level, inverters must share the same HW; PWM level to switch synchronically; and current control level to optimise phase and current sharing through the winding sets.

 

 

 

Electric motor applications

This solution opens the door to new levels of controllability in various advanced applications, including:

• Electric motors with dual isolated windings
• Multiphase machines
• Stacked motors using a single position sensor
• Back-to-back configurations with shared position feedback

The following video demonstrates this functionality using a small test bench, where the primary inverter controls a motor in speed mode and the secondary unit acts as a load by braking and regenerating energy.

 

 

How Primary-Secondary unit Mode Works

The system relies on synchronization at three levels separately:

1. Motor controller PWM synchronization

Synchronizing Pulse Width Modulation across inverters is not strictly necessary, but it helps reduce DC link ripple and switching interference. Without synchronization, PWM timing might drift between devices and impact performance and efficiency.

2. Electric machine position sensing

In a system with single position sensor and multiple inverters, the sensor needs to be read by all devices in order to have the same position measured within the controller. This ensures identical current injection in both transformed axis, direct axis and quadrature axis.

3. Electric motor current control coordination

Each electric motor controller will execute its current control on its own, being the setpoints from the same source, assuming windings are electrically identical. Nevertheless, control synchronization can be achieves as well from torque control level, having in this way a separate motor electrical model for each winding set.

In the case of a 6-phase or 9-phase electric motor, synchronization at the current control level involves incorporating appropriate phase shifts between the multiple phases. This coordination is essential to ensure a continuous and smooth torque output, minimizing pulsations and enhancing the overall performance of the machine

As a remark, in multiphase or multiwinding electric motorss this method will only work out off-the-shelf, if the electric motors’s windings do not share an end connection. 

To end with, this primary-secondary configuration provides on different levels a practical and scalable way to control advanced electric motors, ideal for high power demanding applications. It enables high performance with fewer components.

Learn more about NX’s motor controllers.

In the race to develop more efficient and high-performing electric vehicles (EVs), the spotlight often falls on battery capacity, inverter technology, and lightweight design. Yet, one of the most crucial—and often underestimated—factors in unlocking the full potential of an EV powertrain is the precise calibration of the electric motor controller.

The Role of the Motor Controller in Electric Powertrains

At the heart of every eDrive system lies the motor controller, the silent orchestrator that converts high-level torque commands into real-world traction. It governs how electrical energy from the battery is delivered to the electric motor, controlling torque, speed, and ultimately the dynamic behavior of the vehicle.

Think of it as the conductor of a high-speed symphony: if it misinterprets the score (i.e., torque demand, thermal conditions, or sensor inputs), the performance of the entire powertrain can suffer—resulting in poor driveability, reduced efficiency, or even hardware damage.

Why Calibration Matters

Electric motor controllers come equipped with an array of configurable parameters: current limits, flux weakening curves, torque maps, field-oriented control (FOC) tuning values, and thermal derating profiles, to name a few. Each parameter must be tuned not just to the motor itself, but also to the specific vehicle application.

Benefits of accurate motor controller calibration include:

• Higher system efficiency through optimized torque-per-ampere (TPA) control

• Better thermal management, reducing the need for oversized cooling systems

• Smoother torque delivery, enhancing driving comfort and control

• Maximized power output within safe operating limits

• Improved regenerative braking efficiency, recovering more energy under deceleration

Neglecting proper calibration can lead to suboptimal inverter switching, reduced electric motor lifespan, or increased electromagnetic interference (EMI)—all of which reduce the overall efficiency of the electric powertrain.

Calibrating for Real-World Performance

Effective motor controller calibration is not a one-time operation. It should be treated as an iterative, data-driven process that combines simulation, test bench validation, and in-vehicle fine-tuning.

Some best practices include:

• System identification: Use motor characterization tests to extract key motor parameters (resistance, inductance, back-EMF constants) as input for FOC tuning. For an academic refresher on the fundamentals behind field-oriented control and why accurate motor parameter identification matters, see MIT OpenCourseWare’s Electric Machines notes on field-oriented control (FOC).

• Load profile simulation: Model the expected drive cycles (urban, highway, off-road) to pre-tune torque maps and derating strategies.

• Hardware-in-the-loop (HIL) testing: Validate dynamic behavior in a safe and repeatable environment before on-road deployment.

• Field calibration: Use CAN loggers or telemetry tools to refine controller behavior under real driving conditions.

At NX, we know how demanding that process can be. That’s why we created DeveLinkSTUDIO™, a powerful software tool that helps engineering teams simplify and speed up electric drivetrain calibration.

What does DeveLinkSTUDIO™ do?

Think of it as a smart assistant for engineers working on electric vehicles. DeveLinkSTUDIO™ helps teams:

• Load multiple calibration files at once.
  This allows users to switch between different versions or setups without wasting time.
• See what’s happening inside the motor in real time.
  Live data helps catch issues early and make quick, informed decisions.
• Adjust settings quickly and intuitively.
  No need to dig through complicated menus. Engineers can focus on what really matters.

Why it matters?

In electric vehicle development, time and precision are everything. DeveLinkSTUDIO™ makes it easier for engineers to test, refine, and finalize the performance of electric components. This helps reduce development time and makes the integration process smoother from start to finish.

Since it supports both inverter and Battery Management System (BMS) calibration, the tool is suitable for a wide range of vehicle projects. Whether you’re building a small city EV or a commercial electric truck, DeveLinkSTUDIO™ adapts to your needs.

Smarter tools for a smarter mobility industry

As electric vehicles evolve from niche to mainstream, precision in every subsystem matters more than ever. Calibrating your motor controller is not just a technical detail—it’s a strategic move to ensure your eDrive platform delivers the performance, efficiency, and reliability that today’s EV market demands.

At NX Technologies, we help OEMs and system integrators get the most out of their powertrain through data-driven calibration and performance tuning. Whether you’re building a compact urban EV or a high-performance electric SUV, controller calibration is the key to unlocking your powertrain’s full potential. DeveLinkSTUDIO™ is more than just software. It is part of a broader mission to make electric mobility development more efficient and accessible. By helping engineers work faster and smarter, we’re contributing to the next generation of electric vehicles.

Simple. Fast. Reliable. That’s the NX way of doing things. Discover our Electric Motor Controllers and Battery Management System.

NX Technologies is proud to be part of EfiSOEC, an innovative project focused on advancing renewable hydrogen production with cutting-edge technology. Led by Repsol, this collaboration brings together industry leaders and research institutions to develop high-efficiency solid oxide electrolyzers (SOEC). These electrolyzers will help decarbonize industrial processes and integrate renewable energy sources.

A Collaborative Effort for a Sustainable Future

The project focuses on developing and optimizing SOEC stacks, where electrolysis takes place, and a fully functional module that ensures high performance and efficiency. EfiSOEC brings together leading companies, including Repsol, Técnicas Reunidas, Tubacex, Zigor and NX Technologies, alongside top research centers to design and validate a next-generation hydrogen production system. These are IREC, CNH2, DYMPAP-UCLM, Tecnalia, IMDEA Energía, and CIDETEC. Their expertise in materials, energy storage, and process optimization helps ensure the effectiveness and sustainability of the solutions being developed.

NX Technologies’ Role: Power Electronics for Hydrogen Production

At NX Technologies, we are at the forefront of developing an advanced DC/DC power electronics system specifically designed for hydrogen production using SOEC technology.

Our key objectives include:

• Innovative Power Electronics Design: Creating a cutting-edge DC/DC power electronics system optimized for the new SOEC module.
• Advanced Software Development: Engineering high-performance software to enhance efficiency, stability, and durability.

The Potential of Renewable Hydrogen and SOEC Technology

Renewable hydrogen is produced through water electrolysis using electricity from sources like solar and wind power, making it a clean, carbon-free energy option. EfiSOEC uses high-temperature solid oxide electrolysis cells (SOE), which are more efficient than conventional methods.

A European-backed Initiative for Energy Transition

Launched in October 2022, EfiSOEC is set to conclude by June 2025, with the goal of validating the technology and addressing industrial-scale implementation challenges. With a budget of approximately €4.7 million, the project is backed by the European Union’s Next Generation funds as part of Spain’s Recovery, Transformation, and Resilience Plan, managed by the Ministry of Science and Innovation under the CDTI’s Misiones 2022 program.

Driving Innovation and Decarbonization

EfiSOEC supports the European hydrogen roadmap, which sees hydrogen as a key energy source for reducing carbon emissions. By driving innovation in electrolyzer technology, the project will help cut greenhouse gases and promote a more sustainable industrial sector.

EfiSOEC is taking a crucial step toward a cleaner energy future, reinforcing our commitment to technological innovation and environmental sustainability.

To learn more, click here.

 

Electric vehicles (EVs) are revolutionizing transportation, offering a sustainable alternative to internal combustion engines. Among the critical components that power this revolution, the electric motor and the electric vehicle inverter stands out as a cornerstone of efficiency, performance, and innovation. This article explores what an electric vehicle inverter is, how an inverter works, and why it is indispensable in modern EV powertrains.

What is an Electric Vehicle Inverter?

An electric vehicle motor inverter is an essential electronic device that converts direct current (DC) electricity from the EV battery into alternating current (AC) electricity required to drive the electric motor. It also plays a pivotal role in managing the flow of energy during regenerative braking, converting electric motor AC back into DC to recharge the EV battery.

How Does an Electric Vehicle Inverter Work?

The EV inverter uses switching techniques like field oriented control (FOC) and other control techniques to switch the DC electricity into high-frequency AC for the electric motor. This process involves:

• DC-AC Conversion: The inverter rapidly switches the DC voltage, creating an AC waveform to supply energy to the electric motor.
• Motor Control: Using sophisticated algorithms like Field-Oriented Control (FOC), it optimizes the motor’s torque and speed.
• Thermal Management: Ensures reliable operation by dissipating heat generated during high-power conversions.

ISO 26262 and Automotive Microcontrollers

When designing inverters for electric vehicles, adhering to functional safety standards like ISO 26262 is paramount. This standard ensures that automotive electronics, including inverters, meet rigorous safety and reliability requirements, reducing risks during operation.

Key Features of Automotive Microcontrollers

Advanced microcontrollers, such as the Infineon Aurix TC3xx family, play a critical role in enabling safe and efficient operation of electric vehicle inverters. These microcontrollers offer features tailored for automotive applications, including:

• Multi-Core Architecture: Provides redundancy and enhanced processing power for complex motor control algorithms and safety monitoring.
• Integrated Safety Features: Hardware-based safety mechanisms, such as error correction and fault detection, align with ISO 26262 standards.
• High-Speed Communication Interfaces: Ensure seamless data transfer between the inverter, motor, and other vehicle subsystems.
• Low Power Consumption: Optimized for energy efficiency, which is essential in EV applications.
• Scalability: Supports a wide range of applications, from compact inverters to high-power systems in commercial EVs.

Importance of the Electric Vehicle Inverter

The electric vehicle inverter is critical for EV performance, efficiency, and user experience. Here are its key roles:

• Motor Efficiency: Modern inverters reduce powertrain energy losses, ensuring maximum power delivery from the battery to the electric motor. High-efficiency inverters extend the driving range of EVs, a crucial factor for consumer satisfaction.
• Motor Performance: By precisely controlling the electric motor’s speed and torque, inverters enable smooth acceleration and deceleration, contributing to a seamless driving experience.
• Regenerative Braking: Inverters manage regenerative braking systems, recovering energy during braking and feeding it back into the battery, enhancing overall efficiency.
• Compact and Lightweight Drive System: Innovations in inverter technology have led to more compact designs, reducing overall vehicle weight and improving energy efficiency.

Electric Motor Topologies and Their Implications for Inverters

Electric motors used in EVs come in various topologies, each with unique implications for the design and operation of the inverter and motor control techniques. Some common motor topologies include:

• Permanent Magnet Synchronous Motors (PMSM): These motors are highly efficient and offer excellent torque density. The inverter must implement advanced techniques like Field-Oriented Control (FOC) to precisely manage the magnetic flux and rotor position for optimal performance.

• Axial Flux Motors: Renowned for their compact and lightweight design, axial flux motors demand inverters capable of managing high power density and efficient cooling systems. Their unique geometry often necessitates tailored control algorithms for precision and efficiency.

• Electrically Excited Motors (EEM): These motors eliminate the need for rare earth materials by using electromagnetic fields to generate torque. The inverter must carefully regulate excitation currents and manage complex control strategies to achieve optimal performance.

• Brushless DC Motors (BLDC): BLDC motors offer high efficiency and low maintenance. Inverters for these motors use trapezoidal or sinusoidal commutation techniques depending on performance and smoothness requirements.

Implications for Motor Control Techniques

• Precision Control: The choice of motor topology dictates the control strategy, from FOC to DTC or sensorless techniques.
• Inverter Design: Each motor type places unique demands on the inverter’s switching frequency, thermal management, and power capacity.
• System Integration: The inverter must seamlessly integrate with the motor and vehicle systems, balancing performance, cost, and efficiency.

Conclusion

The electric vehicle inverter is a linchpin in the functioning of modern EVs, enabling efficient power conversion, optimal motor performance, and energy recovery. As EV adoption continues to grow, advancements in inverter technology will be critical to meeting consumer demands for higher efficiency, longer range, and better performance.

At the heart of every electric vehicle’s powertrain lies the inverter—a testament to the ingenuity and innovation driving the future of sustainable transportation. Whether you’re an EV enthusiast, a manufacturer, or a researcher, understanding the role of the electric vehicle inverter is key to appreciating the technology shaping our mobility landscape.

For more information on electric vehicle inverters and their applications, contact us or explore our range of cutting-edge power electronics solutions.

Over the past three years, we have proudly been part of the D-Hub Consortium (VEC-010000-2022-7-HUB-dCO2: Hub de descarbonización para la fabricación adaptativa, modular y multireferencia de VECs), contributing to the advancement of next-generation electric mobility technologies within the framework of the Strategic Projects for the Recovery and Economic Transformation in the Connected Electric Vehicle Sector (PERTE-VEC).

This transformative initiative has been made possible thanks to the support of the Ministry of Industry and Tourism and funding from the European Union’s Recovery and Resilience Mechanism, demonstrating a collective commitment to sustainable mobility solutions and industrial innovation. Moreover, the training project has been carried out under the following file number: (VEC-020400-2022-42-Formación de ensayo y validación de plataforma de control de motores eléctricos).

 

Our Contribution: Next-Generation Motor Controller Development

Within this cutting-edge R&D Consortium, our focus was on the development of an advanced Motor Controller (VEC-020100-2022-196-Diseño y desarrollo de plataforma de control de motores eléctricos para aplicaciones de movilidad en base a semiconductores de banda ancha).

Designed for seamless integration with both IGBT (Insulated Gate Bipolar Transistor) and SiC (Silicon Carbide) semiconductors, this Motor Controller delivers exceptional power density and energy efficiency. These attributes are critical for driving the evolution of electric vehicles, improving their performance while optimizing energy usage.

 

 

A Network of Excellence: The Consortium Partners

Collaboration has been key to the success of this initiative. We are honored to have worked alongside a diverse and talented group of partners, including:

• EBRO
• Barcelona Technical Center
• Biofreshtech
• Grupo Tradebe Medio Ambiente
• Hub Tech Factory
• LGAI Technological Center
• Limpieza Nervion
• Lunagua
• Millor Energy Solutions
• Nuevas Técnicas de Automatización Industrial
• Power Electronics España
• QEV Technologies
• Relats
• S2 Grupo de Innovación en Procesos Organizativos
• Wallbox Chargers
• Zeleros

 

We extend our deepest gratitude to the Spanish Ministry of Industry and Tourism for their leadership and support, and to the European Union Next Generation EU funds, whose backing has been crucial in realizing the goals of PERTE-VEC.

This collaboration reflects the power of public-private partnerships in shaping a greener, more sustainable future for mobility. As we continue to innovate, we look forward to further contributions to the electric mobility ecosystem, driving advancements that will transform the industry.

 

Training on Testing and Validation of Electric Motor Control Platforms

In addition, an internal training course entitled “FORMACIÓN DE ENSAYO Y VALIDACIÓN DE PLATAFORMAS DE CONTROL DE MOTORES ELÉCTRICOS” (“Training on Testing and Validation of Electric Motor Control Platforms”) was carried out. This training project, which is also part of the main tractor project, aims to enhance the skills of workers. It is funded by Next Generation EU funds under the Recovery, Transformation and Resilience Plan.
The project file number is VEC-020400-2022-42, with the primary project code PP_27. The training project budget amounts to €780.

 

Commitment to Innovation and Sustainable Electric Mobility in Europe

Through these initiatives, we reaffirm our commitment to innovation, sustainability, and the continuous development of our team’s capabilities. The collaboration within the D-Hub Consortium demonstrates the impact of shared knowledge and resources in advancing electric mobility. As we look to the future, we will continue to invest in cutting-edge technologies and training, driving progress toward a cleaner, smarter, and more sustainable transportation ecosystem.