Powertrain modularity

This paper outlines the main innovations of the EM-TECH and HighScape projects, targeting a wide range of vehicle applications, including passenger cars and commercial vehicles. Specifically, EM-TECH deals with: i) modular designs of on-board axial flux machines (AFMs) for reducing the implementation costs of scalable centralised powertrains for electric axle (e-Axle) solutions; ii) in-wheel motors (IWMs) integrated with electric gearing, for expanding the high efficiency region of electric corner (e-Corner) powertrains; and iii) the use of permanent magnets deriving from recycling processes to improve sustainability. In parallel, HighScape targets the physical and functional integration of the PE of WBG based traction inverters, onboard chargers, DC/DC converters, and electric drives for auxiliaries and actuators.

Permanent magnet synchronous machines (PMSMs) are still the first choice for use in electric vehicles, due to their unparalleledefficiency and power density. However, they suffer from an inherently limited speed range. As field weakening or the addition of amechanical gearbox deteriorates the efficiency of the drive, it is suggested in this paper to equip the drive with reconfigurationswitches, giving rise to a so-called e-gear. The switches—which are implemented by means of mechanical relays—allow to change the winding connection of the electric machine from a series to a parallel connection and hence to double its efficient speed range.Simulations and experimental results on a 4-kW axial-flux PMSM confirm the feasibility of the concept and prove that the reconfiguration can be conducted in less than 35 ms.

During the last 15 years, the automotive domain has been subject to several disruptive transformations, impacting the full supply chain and enabling the uptake of new services and solutions around road-based passenger mobility and freight transportation. Electrification, CCAM, and SDV are leading to a total redesigning of the vehicle and its components, and very equally to a rethinking of how to deliver value. While software is playing a key role for value creation, it strongly relies on innovative mechatronics platforms and smart powertrain and chassis components as foundation for the SDV of the future. Target of this paper is to introduce the results of the three complementary research projects HighScape, EM-TECH, and SmartCorners, with the focus to deliver consistent innovation along the three following pillars: (a) electrified powertrain and chassis components, (b) vehicle platform and highly integrated corner solutions, and (c) novel control algorithms making use of smart components.

The Horizon Europe projects EM-TECH and HighScape propose innovative solutions for electric traction machines and their WBG-based drives and components, to achieve higher energy efficiency, reduced volume and mass, as well as reduced cost. This paper outlines the main innovations of EM-TECH and HighScape, targeting a wide range of vehicle applications, including passenger cars and commercial vehicles. Specifically, EM-TECH deals with: i) modular designs of on-board axial flux machines (AFMs) for reducing the implementation costs of scalable centralised powertrains for electric axle (e-Axle) solutions; ii) in-wheel motors (IWMs) integrated with electric gearing, for expanding the high efficiency region of electric corner (e-Corner) powertrains; and iii) the use of permanent magnets deriving from recycling processes to improve sustainability. In parallel, HighScape targets the physical and functional integration of the power electronics of WBG-based traction inverters, onboard chargers, DC/DC converters, and electric drives for auxiliaries and actuators.

The transition to e-mobility is disrupting the automotive market. To facilitate this transition, the European Commission with the support of the 2ZERO partnership is calling for experts to engage in collaborative R&D programs, and develop pre-competitive solutions and methodologies supporting the uptake of e-mobility. The target of this paper is to provide an overview of the granted European projects running under the umbrella of the E-VOLVE cluster, illustrating the complementarity of the different initiatives as well as their coverage of the main priorities as defined by ERTRAC. The focus is set on the targets and outcomes of the projects HiPE, HighScape, RHODaS, SCAPE, EM-TECH and Multi-Moby, addressing innovative components (power electronics, e-motors), advanced control strategies, and circularity for safe, efficient, affordable and sustainable e-mobility.