This collaborative Industrial Research project brings together the partners of Shield-Engineering, PUNCH-Flybrid, EMPEL-Systems and PFS-Manufacturing to develop innovative electric-motors, inverters and energy storage systems, ultimately resulting in three new UK manufacturing centres, creating \>750 jobs overall, saving 250,000tonnes CO2/year and anchoring key technology for near-term hybridised ICE/BEV vehicles in the UK. This will enable EMPEL, an SME to manufacture inverters, Shield, a UK Tier2 to evolve into an Automotive Tier1 e-motor manufacturer, PUNCH-Flybrid's technology to be anchored in the UK and PFS-Manufacturing to manufacture automotive flywheels in the UK. The project addresses the automotive council strategic technologies to provide state-of-the-art electric machines and power electronics, alternative hybrid propulsion systems and energy storage systems using flywheel energy storage. This is achieved through development of two innovate products: * Modular, multi-voltage, scalable e-motor with integrated inverter technology, at \>15kW/kg almost double the Automotive Council targets for e-motor power-weight ratio. * Modular flywheel energy storage technology integrated with e-motor and inverters that achieve double the state-of-the-art power-density of battery packs at lower cost. The technology will be validated on two vehicle platforms, a sports-car which pushes the envelope of power-weight ratio for flywheel and e-motor technology, and a light commercial vehicle to prove up to 25% CO2 emissions improvements from fuel saving and brake energy recovery. Key components such as motor internals, forgings and die-casting will be developed within the UK supply chain to anchor the technology in the UK providing growth for UK manufacturing. Overall this project will deliver R&D directly worth £13.27M (including £2M overseas) with £5.63M of APC funding to generate three pilot plants for production of e-motors, inverters and flywheels. Over the following 7 years the partners will invest in scaling-up the three manufacturing plants to produce \>40,000/year e-motors, inverters and flywheels creating \>750 jobs in the process. The technology will also be exploited for off-highway and industrial applications including green technologies. This project will be transformational for UK electric motor and inverter production whilst enabling UK flywheel technology, originally born from F1 racing, to be successfully commercialised.

This collaborative project brings together UK design, manufacturing and supply-chain resources to define how future requirements for this innovative solution for an electric motor with integrated power electronics (inverter) will be successfully configured meeting performance, package, cost, quality and volume demands. This feasibility project will robustly set EMPEL and Shield on the accelerated path to class-leading design and manufacture. This innovative approach is delivered through scalable architecture enabling numerous client applications to be supported with minimal tailoring and unique tooling. The architecture allows the motor & low-cost inverter to be integrated into client's hardware reducing parts count, weight and package dynamics. Collaborative partners: EMPEL Systems bring leading edge motor and power electronics design while accelerating their knowledge acquisition. Shield Engineering (SMT) bring manufacturing know-how and resources.This project drastically advances Shield's plans to support clients with in-vehicle propulsion solutions. Key to the useful outcome of this feasibility study is the contribution of strategic UK based suppliers of core commodities, components and manufacturing equipment. A range of such suppliers will be engaged from the outset to determine optimum specifications which will in turn protect the future scalable architecture requirements and frame the design for manufacture rules. These suppliers will then be equipped to support EMPEL & Shields innovations and growth and the growing broader UK PEMD capability. The project addresses the following investment areas: Power Electronics Manufacture Electrical Machine Manufacture Electrical Steel and Magnet Materials & Manufacturing It will be achieved through definition, value planning and DfM of scalable, core-technology e-motors and inverters for multi-voltage requirements and a large range of motor speeds torques. The products will be configured for stand alone, modular or integrated in-vehicle installation. The project outcomes will include: Higher-volume motor, inverter and key component designs with multi-voltage scalable architecture Design for manufacture guidelines for core processes and components Core process definition backed up by evaluation and verification trials, with estimated manufacturing process-flow, cycle-times and investment requirements at potential volume breaks Production cost indications and challenges Acceleration of automotive market opportunities. Achievement of sufficient TRL and MRL enabling confident transition into future development and exploitation The main focus areas include application of scalable architecture approach, disciplined DfM reviews with fully engaged UK strategic suppliers addressing the challenges and preconceptions of the industry and enabling investment in volume growth.