Powertrain modularity

The target of this deliverable is to define the basic sizes (continuous and peak torque and power ratings, mass, expected available packaging envelopes) of the investigated components and systems for case studies. Furthermore, a set of integrated EM-TECH corner modules and on-board electric drive solutions for electric vehicles are defined to cover the widest possible range of vehicle segments. This deliverable also describes the associated machine control such as the cooling control and the inverter control for the new machines, and the vehicle controls to exploit the benefits to vehicle performance brought by the new machines, including the wheel slip control, the motor regenerative braking and braking blending, and the anti-jerk control.

This report is dedicated to the implementation of project tasks aimed at developing and validating a new generation of electric drives for automotive transport. The project considered two key technological lines: the use of In-Wheel Motors (IWM) in an e-corner configuration, and the use of axial electric machines as part of an e-axle system. The main objective of this stage was to preliminarily test the performance of individual components and subsystems, as well as to validate control algorithms in conditions close to real-life operation.

The utilization of IWMs and axial motors creates opportunities for improvements in energy-efficiency, improved dynamic characteristics, and the implementation of new vehicle motion control functions, including the distribution of traction and braking forces at the level of individual wheels. These technologies create the basis for more flexible powertrain architectures and expand the potential of integrated control systems.

The report presents the results of experimental studies conducted on assembled test benches to evaluate the correct functioning of control elements and analyse the effectiveness of the interaction between hardware and software components of the e-corner and e-axle systems.

Description of the innovative in-wheel motor design with integrated direct cooling and mechanical e-gear developed in the EU-funded project EM-TECH. 

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.

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.