EU funded projects

• EMPOWER

  Eco-operated, Modular, highly efficient, and flexible multi-POWERtrain for long-haul heavy-duty vehicles.

  EMPOWER addresses in full the expected outcome and scope of the HORIZON-CL5-2022-D5-01-08 topic by delivering two flexible, modular, and scalable zero-emission heavy-duty vehicles (ZE HDV) belonging to the VECTO vehicle group 9 (6×2 rigid trucks), with a gross vehicle weight equal or above 40 tons. One vehicle is powered by a Fuel Cell (FC) system and has a driving range of 750 km, while the other is powered by a battery-electric powertrain, and has a driving range of 400 km.

  Both vehicles will be delivered at TRL 8 by the end of the project (end of 2026) and are expected to approach the market by 2029. Within its technical activities, EMPOWER will:

  • design, implement and deliver technology bricks: (1) a modular vehicle system architecture, (2) a modular low-voltage E/E architecture, (3) a FC system with high reliability and extended operational lifetime with a modular energy storage, (4) a highly efficient e-axle, (5) an optimised thermal- and energy management, (6) an optimised HVAC system featuring CO2 as refrigerant and infrared heating panels, (7) an electrified distributed braking system, (8) digital twin models of the demonstrators, (9) an innovative Human Vehicle Interface for optimised control of the vehicle systems, featuring Vehicle-to-Grid communication and eco-routing, (10) a fleet management system for the integration of ZE HDV into the fleet, (11) an overall LCA and TCO assessment, and (12) the operation of a green hydrogen infrastructure for ZE HDV.
  • demonstrate the driving range and real-world operation performance of the two ZE HDV in five different long-haul and regional distribution use-cases, including cross-border corridors between different European member states.

  The modular and scalable EMPOWER technology is transferable to VECTO vehicle groups 4, 5, and 10, and it is designed to achieve the total cost of operation parity against the conventional 2020 baseline diesel truck by 2030, targeting a production volume above 10000 vehicles/year.

  

• EMTECH

  Innovative e-motor technologies covering e-axles and e-corners vehicle architectures for high-efficient and sustainable e-mobility

  EM-TECH is a research project funded by the European Commission. It started on January 1st, 2023 and will last for 36 months. EM-TECH brings together 10 participants from industry and academia to develop novel solutions to push the boundaries of electric machine technology for automotive traction, through: i) innovative direct and active cooling designs; ii) virtual sensing functionalities for the high-fidelity real-time estimation of the operating condition of the machine; iii) enhanced machine control, bringing reduced design and operating conservativeness enabled by ii); iv) electric gearing to provide enhanced operational flexibility and energy efficiency; v) digital twin based optimisation, embedding systematic consideration of Life Cycle Analysis and Life Cycle Costing aspects since the early design stages; and vi) adoption of recycled permanent magnets and circularity solutions.

  

  The proposed innovations will be implemented in new series of radial flux direct drive in-wheel motors characterised by so far unexplored levels of torque density (>150 Nm/litre, >50 Nm/kg), and on-board single stator double rotor type ironless axial flux machines providing power density and specific power levels in excess of 30 kW/litre and 10 kW/kg. The solutions will address both passenger car and van applications (continuous power levels of 50 kW - 120 kW), providing competitive costs (<6 Euro/kg for a production of 100000 units/year), and leading to significant reduction of motor energy loss during real vehicle operation (>25%), and to >60% decrease of the rare earth content, including implementation of magnet recycling solutions. EM-TECH obtained the support of several car makers (AUDI and Changan UK), which will strengthen the exploitation strategy. EM-TECH will further directly contribute to the relevant European Destination and KSO C and A, by supporting the establishment of a European leadership in the sector of key digital, enabling and emerging technologies, and the development of the respective value chains.

  

• GEN1200

  Ultra-Efficient Highly-Integrated 1200V Powertrains for Electric Vehicles Enabling Next-Gen Charging Speeds and Compatibility Across Charger Generations

  Current mass-market electric vehicles (EVs) commonly operate at a voltage level of 400V. There is however a clear trend to increase the voltage level towards 800V and beyond, as these higher voltages allow for faster charging and lower thermal loads in the system. GEN1200 will focus on modular and scalable 1700V SiC-based power electronics solutions for highly-integrated 1200V powertrains, encompassing technologies for ultra-fast charging while ensuring compatibility with existing charging infrastructure, maximally exploiting the opportunities enabled by higher voltages. The project activities will particularly result in: (i) innovative 1700V SiC power electronics systems with multiple use of components, e.g. the traction inverter will also embed the functionality of backwards compatibility with 400V or 800V DC charging and on-board AC charging; (ii) 1200V electric axle solutions with electrical, thermal and mechanical integration of the power electronics, electric machine, mechanical transmission, and a selection of auxiliaries; (iii) ultra-fast 350 kW charging of novel 10C battery modules with integrated electronics and a modular wireless battery management system for 1200V battery packs. Innovations will be tailored to C-segment vehicles but extrapolation towards other segments will be considered. All activities will be supported by the development of digital twins, as well as control solutions tailored to 1200V systems and for reducing power losses in partial load, and life cycle analysis. Innovative testing methodologies, combining classical component and system characterisation, x-in-the-loop, and experimental vehicle assessment, will cover the wide range of relevant aspects, including efficiency, durability, electromagnetic compatibility and interference, as well as charging performance and sustainability. GEN1200 will leverage the complementary competences and exploitation potential of 3 academic partners, 1 RTO, 2 SMEs and 2 large industrial players.