Large heavy commercial vehicles are responsible for 39% of the global CO2 emissions from road transport and have a significant detrimental impact on urban air quality and public health.
Utilising a novel "patented" kinematic gear transmission configuration, combined with advanced control software and Helix power dense Motor/Invertors, Involution Technologies will demonstrate a new electric drive unit (EDU) suitable for application in any large on/off-highway vehicle ranging from 25 to 80+tonnes GCVW, including freight transport, transit bus, coach, construction, and agricultural machines.
The core common design technology provides both a central drive and e-axle configuration that may be retrofitted into existing vehicles or applied to dedicated EV platforms.
Product types: -
1\. Central drive EDU single-axle, 4x2 or 6x2, 25-44 tonne
2\. Central drive EDU Multi-axle 6x4, 8x8, 44 -- 80 tonne
3\. 13-tonne E-axle.
Acceleration, gradeability and maximum speed will match or exceed the existing ICE driveline performance whilst operating at zero emissions. Novel control techniques increase part/regenerative load, and efficiency, providing operators with a vehicle performance which is robust to varying usage patterns including payload and drive cycle effects.
The **INVO-EDU** will be demonstrated, and performance tested and brought to the point of customer vehicle trails within the scope of this project.
The INVO-EDU provides **instant and uninterrupted torque and power** delivery across the entire vehicle operating envelope, equivalent to an ICE/ automatic transmission driveline and without the torque-interrupts of an ICE AMT driveline. To the end user, this feels like a direct-drive electric machine with performance characteristics way beyond any known electrical machine in the marketplace.
Key characteristics include: -
37 kNm prop shaft stall torque. (Giving 110 kNm of wheel stall torque)
225 to 540kW continuous power rating with a 15:1 constant power speed ratio.
Continues/seamless torque from vehicle launch to full speed.
3 to 8% lower energy use depending on the duty cycle verse other EDU's.
High continuous power & torque density electric machines \>6 kW/kg and 25Nm/kg
Low new application engineering cost through inherently high system and functional safety.
Low service cost with no wearing of synchronizers or friction clutches.
No specialist driver training requirements.
Best performing HGV EDU in the marketplace.
\*Unmatched stepless torque over a wide speed range.
\*Unlimited power.
\*High duty cycle efficiency -- Best in market.
\*Compact. (Most competitive)
\*Simple robust design. (Long life/ low maintenance)
\*Advanced control system providing optimum efficiency and stepless gear shift.
Involutions INVO-EDU is the next generation of Electric Drive Unit for heavy-duty, zero-emissions HGV applications, that matches or exceeds the performance of existing ICE drivetrains and is capable of being retrofitted into existing vehicles by simply removing the ICE and gearbox and connecting the INVO-EDU directly to the prop shaft.
INVO-EDU an Electric Drive Unit that can power any heavy commercial vehicle with a performance to match or exceed the replaced ICE driveline, whilst providing the highest duty cycle efficiencies available in the electric heavy-duty commercial vehicle market. The high efficiencies achieved with the INVO-EDU via the continuously variable control capability make it possible to achieve the required driving range within the practical installation of the battery, fuel cell and hydrogen tanks on the vehicle.
Involutions partner in this project is Bramble Energy, their innovative fuel cell will complement the INVO-EDU, increasing the UK content of the total drive solution, giving a very robust fuel cell, critical for this type of application and at a significantly lower cost, which is a key factor, given the fuel cell capacity required.
The **INVO-EDU** provides:
1\.**Instant and uninterrupted torque** (stall torque 37 kNm) **and Power delivery_,_ (**300kW/650 kW peak) feels like direct drive, performs like multi-speed**.** Start ability 39%, Acceleration 41.4 secs, Vmax 120 kph
2\.**Wide operating efficiency,** Variable ratio drive extends the efficient operating window of the base electric machine. (HHDDT composite efficiency 91.1%)
3\.**Robust 100% recyclable motors**, 8500 rpm AEM SR electric machines. Robust to passive rectification and over-voltage failures.
4\.**Robust and Reliable Transmission**, built for improved reliability with inherently fewer potential failure modes, no synchronisers -- no friction clutches -- no rotor cooling seals -no double engagement failure modes.
5\.**Power Dense,** 2.4 kW / litre
6\.**Commercially competitive**.
Bramble Energy Fuel Cell provides:-
1.Target cost 5x cheaper
2.4x fewer components
3.Fully customisable
4.£0 CAPEX spend
5.Robust and durable
Involutions INVO - EDU is the next generation of Electric Drive Unit for heavy-duty, zero-emissions HGV applications, that matches or exceeds the performance of existing ICE or Electric drivetrains and is capable of being retrofitted into existing vehicles by simply removing the ICE and gearbox and connecting the INVO-EDU directly to the prop shaft.
The INVO-EDU provides:-
1\.**Instant and uninterrupted torque and Power delivery_,_** Feels like direct drive, performs like multi-speed**.**
2\.**Wide operating efficiency,** Variable ratio drive extends the efficient operating window of the base electric machine. (HHDDT composite efficiency 91.1%)
3\.**Power Dense 100% recyclable motors**, 8500 rpm SR electric machines.
4\.**Robust and Reliable Transmission**, Built for improved robustness with inherently fewer potential failure modes, No synchronisers -- No friction clutches -- No rotor cooling seals -No double engagement failure modes, Robust to passive rectification and over-voltage failures.
**INVO-EDU** an Electric Drive Unit that can power any heavy commercial vehicle with a performance to match or exceed the replaced ICE driveline, whilst providing the highest duty cycle efficiencies available in the market.
**Critical Facts**
Continuous Power 300kW,
Peak Power 650kN
Stall Torque 37kNm
Efficiency 90.2% (WLTP), 91.1% (HHDDT Composite)
Torque-interrupt free.-There is no output torque discontinuity following a regime change
The power recirculation is neglectable following a regime change
Gradient @50kph4.7% (2.7 degrees)
Gradient @60Kph3.8% (2.2 degrees)
Gradient @100kph2.3% (1.3 degrees)
Acceleration 41.4s
Vmax 120kph (gradients up to 0.75%)
Startability 39% (21.3 degrees)
Large heavy commercial vehicles are responsible for 39% of the worlds global emissions and even more significant is the impact of heavy diesel engines in city centres on air quality. The **INVO-CVT** electric drive train will be used on the largest HGV's enabling full electric, zero emissions operation. Adopting this transmission on HGV's means that the large construction tipper lorries on building sites, vehicles delivering container freight, inter-city coaches delivering people to the city can operate 100% electrically, on zero emissions.
The transmission is always connected to the vehicle wheels without interruption in drive, to give the optimum traction. Power associated with slowing the vehicle down in overdrive is fully recovered by the electric drive system. These features significantly reduce the total duty cycle energy requirements of the vehicle, by an anticipated 20%.
The **Invo-CVT** is targeted to be retro fitted into the existing vehicles and to be cost competitive against diesel powertrains. **Invo-CVT** is a game changing drivetrain for very heavy vehicles that can be rapidly introduced into production for new and existing heavy vehicles to have an immediate impact on emissions. The time is right for the **INVO-CVT,** which is 100% UK manufactured and with 100% UK owned IP.
"The high-cost of electric powertrains is limiting the speed of uptake of electric and hybrid-electric vehicles.
This project aims to deliver a fully-integrated e-axle (power electronics, electrical machine and gearbox) which will beat UK Automotive Council 2025 cost targets for these technologies and be suitable for UK manufacture. This will simultaneously increase the speed of uptake of electric vehicles, reduce the requirement for government subsidy and increase the number of skilled manufacturing jobs in the UK.
The e-axle will beat 2025 cost targets by utilising a novel polymer-bonded rotor and ultra-low-cost roll-up stator construction in the electrical machine. The power electronics will combine an optimised power stage layout with novel control and cooling techniques. Advanced system-level optimisation tools will be used to size the e-axle and ensure the best gearbox topology is selected for the application. The e-axle will be demonstrated in a mule vehicle by break-through electric vehicle OEM Detroit Electric."