Project acronym: EUNICE Grant agreement no.: 285688 Call ......FP7 SEVEN FRAMEWORK PROGRAMME THEME:...

© Copyright EUNICE Project 2012. All rights reserv edFP7 SEVEN FRAMEWORK PROGRAMME THEME: GC.NMP.2011-1, GC.SST.2011-7-7, ICT

Grant agreement no.: 285688Call: FP7-2011-GC-ELECTROCHEMICAL-STORAGE

Eco-design and Validation of In-Wheel Concept for Electric Vehicles

Project acronym: EUNICE

www.eunice-project.eu

The information contained in this document is proprietary and confidential.This document may not be duplicated, published or disclosed, in whole or in part, without the prior written permission of the EUNICE

coordinator.

© Copyright EUNICE Project 2013. All rights reserv edFP7 SEVEN FRAMEWORK PROGRAMME THEME: GC.NMP.2011-1, GC.SST.2011-7-7, ICT 2

1. Introduction: Why EUNICE?2. Target Vehicle Specification3. Key technical aspects of EUNICE solution4. Project status

Table of Contents: EUNICE project


Introduction: Why EUNICE?

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Source: ERTRAC draft roadmap june 2012

Motor in Wheel is an interesting alternative for second and third generation EV´s



Future Vehicle Vision:

• Low “floor” for maximum design freedom (future platforms, battery & structure)

• Performance & drive-ability, mostly on urban environment

• Plug & play + Modularity of drive system

• Functionally safe “E/E architecture”

• Environmentally friendly

So basically we are looking at something like this…



Lohner-Porsche electric with motor in wheel !!!



6

Tesla Model S exploits the possibilities of electric powertrain, butis it still “room” for improvement?

Electric drive & gearbox



7

Vehicle architecture can be simplified by “in wheel” motors

Additional elementsbesides of the e-motor, such as inverter, coolingrequire much space

EUNICE integrates e-motor, gearbox , power inverter and cooling system into the wheel assembly


Platform structurewith flat battery

Front car boot

Rear car boot

Roomy interior


Low CoG

Maximum design freedom for B segment cars


TARGET VEHICLE SPECIFICATION

Future EV s for “B” segment, main characteristic summary: • 4 seats• 1150kg (including driver)• 1372kg (3 passengers and driver)• Good drive-ability up to 140km/h• 0 to 100km/h: less than10s• Assumptions for future optimized “B segment” Vehicles:

– Optimized Structure– Optimized Battery– Significant simplification of sub systems– Enhanced aerodynamics (active?)– Improvements in high temperature e-drives (materials &

components)

Specification has been reviewed with OEM´s in dedicated workshops



Driving cycle has been defined based on ARTEMIS Cycle.



VEHICLE PERFORMANCE REQUIREMENTS:Based on the available Technology Demonstrator vehicle, a torque / speed curve has been defined for 1350kg , covering EUNICE cycle points

Torque/ speed curve to cover EUNICE duty cycle

Improved driveability

Eunice duty cycle


DRIVEABILITY REQUIREMENTS:Validation criteria

TARGET VEHICLE SPECIFICATION REVIEW

Ref. B segment

EUNICE

EUNICE tech demonstrator

Dev. Phase

Vehicle dynamics is critical for the adoption of motor in wheel technologies, demanding new suspension design.


PHYSICAL INTEGRATION REQUIREMENTS

All the EUNICE components shall fit within the space envelope existing in conventional “B” segment car

An electronic mock up (CAD model) has been “re created” based on “B” segment vehicle.

EUNICE solution can be implemented in a typical McPherson with minor changes to attaching points. (subframe)

TARGET VEHICLE SPECIFICATION REVIEW


KEY TECHNICAL ASPECTS

EUNICE key technical aspects:

• High power density , using PMSM Axial flux and integrated reduction gear (31 kW + 31kW =62 kW)

• High torque output (more than 1000Nm per wheel, >2000Nm)

• Transient peaks of 85kW for improved driveability

• Integrated air cooling system

• Unsprung mass increase of 30kg per wheel with re-designed suspension (25kg in series production)

System can be scaled up in power, if water cooling is used. (>150kW )



Baseline design (Standard electric vehicle):

– A single radial flux electric motor– Torque in radial machine : k x r^2– Limited cooling surface (outer cilinder & winding heads)

Proposed design (EUNICE)

– 2 axial flux machines– Torque in axial: k x r^3– Multiple cooling surfaces (4 faces & winding heads)

Why 2 axial flux motors are better than a single radial in terms of power density and cooling capability ?

Axial flux typology is optimum for this application


Porsche 917-1971:

• Powertrain max. efficiency: 25-30% maximum?

• Peak output mechanical power: more than500kW

• Hundreds of kW of heat to be evacuated frommotor block

With forced air cooling…

Other famuous examples:

• Citroen DS• Citroen 2CV• Porsche 911• Volkswagen Beetle


Forced air cooling combined with aerodynamic can be used for efficient heat removal


PROJECT STATUSE-corner functional analysis & module development

Based on target specifications defined by Pininfarina, project partners areexecuting research activities at sub-module level:

• GKN-EVO / Driveline develop the axial flux electric motor and integratedreduction gear

• Infineon is developing the integrated power electronics module

• Magneti Marelli is developing the suspension system based on a McPhersonstrut

• Hayers Lemmertz is developing a specific wheel that will reduce unsprungweight and enhance heat ventilation

• AIT is developing detailed CFD models for cooling concept design

• Tecnalia is developing a multi domain simulation tool for identification oftemperature and system optimisation.

• Clepa, AIC, IVL, CIE, DENN are involved in Ecodesign, dissemination andaltenrtive process evaluation for series manufacturing of system



Suspension development

Air cooled power electronics module

Assessment of wheel airflow

Thermo mechanical electricalmodelling

Active wheel

Axial drive & gear development

Vehicle dynamics assessment

Integration is critical for project success



Testing and validation of main components:

• Test bench of air cooled electronics: On going

• Test bench of e-drive: Q3 2014

• Vibration rig for dynamic endurance: Q4 2014

• Integration into “B” segment vehicle for driveability test: Q1 2015


Grant agreement no.: 285688Call: FP7-2011-GC-ELECTROCHEMICAL-STORAGE

Eco-design and Validation of In-Wheel Concept for Electric Vehicles

Project acronym: EUNICE

www.eunice-project.eu

THANK YOU

Project Coordinator Alberto Peña , Tecnalia Research & InnovationTel: +34 946 430 850, E-mail: [email protected]

Start date / Duration of the Project September 1st, 2012. (36 months)

Website http://www.eunice-project.eu

THANKS FOR YOUR ATTENTION

For further information, please contact Project Coordinator or visit the website

Project acronym: EUNICE Grant agreement no.: 285688 Call ......FP7 SEVEN FRAMEWORK PROGRAMME THEME:...

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