Public Funding for Alcon Components Limited

Energy capture through re-gen braking reduces the duty on a conventional friction brake system. However the ultimate energy storage capacity, weight & residual drag of the friction brake systems have remained unchanged. This is because emergency duty cycles (e.g. ABS) require independent control of the tyre contact patch. A single electric machine (EM) per axle mechanically couples both wheels and cannot offer the level of control required. Consequently significant friction brake downsizing or integration has not been realised to date. That said, multiple independent EMs (1 per corner) do offer the opportunity for integration with the friction brake. This consortium aims to integrate the brake and propulsion systems together into “Integrated Torque Actuator Modules” (ITAMs). It is anticipated these modules would be smaller, lighter and lower cost, yet realise significant vehicle attribute enhancements. The consortium will design, develop and prototype the ITAMs and establish whether they are capable of; 1. All duty cycles including ABS and dynamic stability control (DSC), 2. Zero residual drag torque, 3. Brake emissions capture and storage. 4. zero servicing.

The safe deployment of autonomous and remotely operated vehicles is only possible with mature and fault-tolerant vehicle control systems where any kind of vehicle failure is taken into consideration, including overriding autonomous driving software in the event of significant computer system failures. These control systems, also called drive-by-wire (DbW) systems, are not yet commercially available to the vast majority of vehicle manufacturers, thereby severely limiting the potential roll-out of autonomous vehicles across all markets. The SAFE (Systems for Autonomy in Fail-Operational Environments) project will develop and test technologies applicable for both NUIC (No User In Charge) and UIC (User in Charge) vehicle platforms integrating novel safety systems and subsystems capable of achieving SAE Level 4 (L4) autonomy within a wide range of Operational Design Domains (ODDs). StreetDrone will collaborate with two innovative SME tier 1 suppliers, Chassis Autonomy and Alcon, bringing together an overall fail-operational architecture integrating mission critical steering and braking sub-systems. These are safety critical vehicle systems that ensure lateral and longitudinal control of the vehicle at all times, even in the event of a single point fault of failure. A key part of developing the wider supply chain for the CAV sector within the UK is providing safe and secure vehicle hardware for all other downstream systems to be developed and tested upon; without this enabler in place, organisations working on various elements through the self-driving stack cannot successfully develop and validate their products let alone place them into commercial operation. Together, these three innovative UK-SMEs will work alongside the Centre of Automotive Engineering at University of Surrey, developing a credible solution, tested in simulations of multiple real world contexts, and proven on the track by end of 2024, and ready for meeting anticipated Level 4 safety regulations.

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"**AID-CAV** brings together four UK SMEs with two research organisations to develop some of the key ""vehicle platform"" technologies that will be required for the rapid development of the next generation of autonomous vehicles -- vehicles that will have enhanced capability and performance. Lead partner Delta Motorsport will develop its existing vehicle dynamics control framework to make it suitable for autonomous vehicles based on the extended control authority it will have -- not just traction motor(s) but steering and brakes as well. Delta will convert one of its E-4 Coupe electric vehicles such that it can be used by the consortium to validate the hardware and software being developed. Titan and WMG will develop a bespoke high-performance servo motor which, combined with a new power electronics controller, will create a high-reliability steering mechanism featuring the appropriate level of redundancy for L5 autonomy. This development will build on Titan's existing knowledge of EPAS systems in the niche automotive and motorsport sectors to provide steer-by-wire (SBW). Working closely with Titan, WMG will bring significant expertise to the project in advanced power electronics solutions, together with electric motor design, manufacturing processes and implementation. Alcon will enhance its existing motorsport braking systems by combining the functions of brake actuation and ABS modulation (including brake-by-wire, BBW) into a single device. System response is improved (and thus system performance and safety) while reducing weight and complexity. Calibration is also simplified, reducing the risk of negative interaction between the two sub-systems. Cranfield will develop an autonomous driving controller accounting for the complex vehicle dynamic behaviour in limit handling conditions and exploiting the enhanced control authority available through multiple actuators (allowing individual wheel torque control) and the novel flexible control architecture. Potenza will develop the safety case for the system architecture and thus for the sub-systems, using an out-of-context methodology to provide a template for applying the systems to other vehicles. The technologies will be developed within the framework of ISO26262 Edition 2 and will be designed to meet the derived safety requirements. All systems will have the necessary flexibility to adapt -- quickly and at relatively low cost -- to a wide range of vehicles, including small cars, trucks, off-highway and high-performance vehicles."

"Cast iron brake discs are the predominant brake solution used in passenger cars. These brakes are detrimental to fuel consumption due to their onerous weight. They are also a significant human health hazard because of the metal particulates that are emitted as they wear. These brakes are predominantly used in passenger cars and are the second largest contributor of particulate emissions from a vehicle, a significant contributor to air pollution. Keronite International Ltd and Alcon Components have developed a wear-resistant lightweight brake disc for use in passenger vehicles to overcome the aforementioned problems. We have proven the concept with successful trials and testing carried out with a leading UK University and an expert vehicle systems test house. To take our solution to the next level, we have formed a development collaboration with Alcon Components, who will provide the expert knowledge and skills in the development and manufacture of advanced braking system. Together we will develop an early stage prototyped for an innovative lightweight low wear brake disc for full dynamometer testing and initial in-vehicle trials. By overcoming the limitations of existing coatings and state-of-the-art solutions, our technology will address an urgent unmet market need. In turn, we expect to generate significant exports for the UK economy and in the process create numerous UK based high-skilled jobs."

Vehicle efficiency, regardless of the powertrain type, can be increased through several strategies, including reducing weight, aerodynamic drag, reduction in rolling resistance and powertrain efficiency. Out of all, weight reduction is considered to have the greatest potential to increase vehicle efficiency and thus to reduce the CO2 emissions. The objective of the FLAC project is to progressively develop and demonstrate a portfolio lightweight automotive components with increased efficiency and functionality utilising an integrated SLM design methodology, a novel class of lattices, new aluminium alloys for SLM and demonstrate the viability of selective laser melting as a manufacturing route.