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.

This report (D6.1) focuses on the integration and testing of two advanced powertrain components: the smart e-corner and the smart e-axle. The In-Wheel Motor (IWM) from ELA is integrated into the smart e-corner at TUIL and the baseline On-board Axial Flux Motor (AFM) is mounted on the powertrain test rig at USR. In parallel, a smart e-axle will be implemented at USR, while the dSpace Scalexio Rapid Prototyping system at TUIL will operate a virtual Vehicle model within a X-in-the-Loop (XiL) framework. This setup allows for distributed real-time simulation and control across both sites.

The experimental configurations will be equipped with comprehensive instrumentation—voltage, current, torque, temperature, and vibration sensors—to measure electrical and mechanical performance, thermal behaviour, and Noise, Vibration, and Harshness (NVH) characteristics. Control and monitoring will be coordinated through the dSpace platform and through a secure Virtual Private Network (VPN) connection between USR and TUIL.

Indirect cooling concept: The challenge was to design and optimize a novel indirect cooling strategy based on a cold plate for the rotor of the yokeless axial in-wheel motor.

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.