APC25 PULSE

Project overview

Delivering revolutionary EV technologies combined with new UK manufacturing capabilities for power-electronics products, PULSE will bring new, UK-developed, power-electronics products and a dedicated make-like-production pilot line.

Protean will deliver an advanced 800V Twinverter and in-wheel drive solution and Unipart will develop a flexible assembly line for power-electronics systems, including Viritech’s advanced DC-DC 800V converter.

The collaboration builds on sensor technology from Transense and recycling processes from Hypromag, improving efficiency and lifecycle sustainability, whilst industrialising best-in-class research from Coventry University and Warwick Manufacturing Group.

Protean Electric: PULSE – Power-electronics Upscale for Localisation and Sustainable Electrification - Advanced Propulsion Centre

Project objectives

The PULSE Project is a £11m collaborative effort focused on advancing power electronics manufacturing through innovative digital and metrological techniques, sustainable practices, and the development of soldering technology. This initiative aims to foster high-efficiency production and bolster the business case for localizing the manufacturing of power electronics.

Coventry University will play a crucial role in the project, primarily focusing on the following areas:

• Digital and Metrology:
  We will define and integrate digital layout plans and metrology for both low (5,000 units) and high-volume (50,000 units) production systems.
  Our team will support the design and execution of advanced plant simulation models to optimise production efficiency.
  We will conduct comprehensive benchmarking and testing of metrology equipment, ensuring its integration within digital models and production processes.
• Sustainability Initiatives:
  We will provide advisory support in Product Lifecycle Assessment (LCA) and the implementation of Digital Product Passports, focusing on integrating recycling content and sustainable manufacturing practices.
• Selective Soldering Development:
  Our research will centre on optimising selective soldering processes to enhance product integrity and manufacturing sustainability. This includes designing test PCB boards, characterising low-temperature solders and validating solder joint integrity through extensive testing.
• Communication and Dissemination:
  The university will actively engage in conferences, publications and dissemination events to share the progress and results of the project.