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.

A comparison between different slot/pole combinations of axial flux electric machines is presented in this poster. The main objective is to classify these structures according to torque density and electromagnetic performance, based on the specifications of a medium-sized electric car. The study is carried out using 3D-FEA calculations.

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.

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.

Description of the developments on the high power density axial flux motor prototype for the EU-funded project EM-TECH. 

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.