Awaiting Public Project Summary
SANGREAL builds upon the UK's leading position in sustainable automotive technologies, delivering cost and environmental benefits to industry and social stakeholders. Our Consortium includes innovative UK technology development companies, Tevva and AEM who both have world class experience of commercial vehicle electrification.
SANGREAL will design and bench-test an innovative transaxle and vehicle control system and integrate this into a range of different GVW size commercial lorries.
SANGREAL accelerates the development and commercialisation of Tevva's current Medium Duty Commercial Vehicle EV powertrain technologies, including an AEM motor set, capable of operating safely in a range of climates fully Zero emission in the target "back to base" logistics market operating 7.5-19t vehicles, a sector overlooked by existing OEMs. This proposal leverages previous UK Government investments to deliver a suite of novel, compact, low and zero emission commercial vehicle powertrain solutions compliant with ISO26262-automotive and ISO13489-off road. A substantial part of the investment will develop advanced, control software based around a patented time-triggered vehicle control methodology with cloud-based telematics. These new technologies will enable OEMS to cost effectively introduce vehicles with market leading performance for a lower total cost of ownership than existing solutions.
SANGREAL builds on the current generation demonstration and validation vehicles scheduled for deployment in 2020. This will provide significant dissemination and exploitation opportunities and data capture over \>1 million miles of real world operation informing SANGREAL design and development processes during this project.
The system will combine excellent flexibility, low mass and small form factor, with low levels of noise and vibration. The modular design enables the vehicle OEMs to offer the optimum combination of battery capacity, weight and optional H2 Fuel cell range extender to suit the end users a variety of duty cycles, eliminating range anxiety and battery management issues for operators. The optional H2FC removes 100% of tailpipe emissions than Tevva's current diesel range extender solution whilst maintaining operational capability. Enhanced battery thermal management will support greater deployment opportunities in previously unsuitable climates such as India and Norway.
The Consortium provides cutting edge technology and expertise in e:powertrains, electric machines, battery packs and power electronics, range extender systems and embedded systems (vehicle control units VCUs) and vehicle telematics. The Advisory Group / steering committee includes expertise in Powertrain, Power Electronics, Safety, compliance, battery technology and Vehicle usage and end users UPS and Kuehne & Nagel and will invite on and off-road OEMs.
"Project VALUABLE's key objectives are to develop commercially viable metrology and test processes as well as new supply chain concepts for recycling, reuse and remanufacturing of automotive lithium-ion batteries to create a complete End-of-Life (EoL) supply chain network within the UK.
The consortium's vision is to 1) increase the value-add of the battery supply chain in the UK, 2) decrease the environmental impact, and 3) optimise future battery design for EoL. By bringing together many disparate parts of many sectors, the project will provide an efficient and effective route to providing second life battery applications, whilst reducing the packs / cells being fed into the waste streams.
The project will investigate key areas that are providing difficulties in dealing with automotive batteries at their EoL: 1) the lack of reliable and cost-effective test methods, 2) the lack of remanufacturing/recycling and reuse processes, 3) the lack of effective value chains, and 4) lack of design considerations for EoL in battery design.
To implement efficient processes, the project will investigate and develop advanced 'machine vision' capabilities, to determine which packs have second life potential and at what level and which are for recycling.
This development of advanced testing capability in the EoL processing line, will enable the consortium to explore significant value chain applications for end-of-life batteries, ranging from remanufacturing to go back into the same vehicle model, to use in lower demand mobility applications, through to use as energy storage mediums for the energy market. The test results will also aid future first life battery pack design, providing OEMs and battery producers with routes to both realise additional value from future applications for used batteries and to move towards 95% recyclability.
In conjunction with the development of new designs and processes, the project team will also explore the growing legal and regulatory issues surrounding the battery producer responsibility / waste classifications in the UK and Europe.
In addition, not only will the battery cells be assessed, but the charge controllers, outer jackets, and other components. Reuse of these products contributes to the recycling targets, but also supports improved material recovery routes through better material separation.
The project brings together partners across the supply chain, developing new EoL testing techniques, and in creating a UK-based EoL supply chain. The project is not only supported by the supply chain but also an industry-wide OEM support represented in a guiding advisory group."
Tevva will deliver modelling software that at a glance, can provide requirements specifications to
Engineering and development teams, but that can also be used by Sales and Marketing to demonstrate to
customers the performance profile of their fleets when they adopt the Tevva Electric Range Extended
Technology. Allowing them to tailor their choices of battery pack size and range extender capability when
purchasing. This configurability will ensure customers can purchase vehicles that meet their
requirements without spending thousands of pounds on battery packs they can utilise to the full and
range extenders that are over capacity. This all adds up to Tevva offering products at a lower total cost of
ownership that still delivers the capabilities needed by a modern, environmentally concious fleet.
UK Government AQ strategy states that there are over 50,000 premature deaths yearly due to AQ pollution. Emissions from transport are a key contributor to poor AQ. Vehicles which have an internal combustion engine and an electric only range can offer zero emission (ZE) operation but cities lack the ability to monitor and control the vehicles. Project ACCRA - a collaboration between Dynniq, Tevva, EarthSense, Transport Systems Catapult, Cenex and Leeds City Council - will address this problem by developing a system capable of allowing remote control of a vehicles energy management system to ensure ZE operation where it has maximum benefit to AQ. The operation will be demonstrated in a proposed Clean Air Zone in Leeds. Under the overall management of the Transport Systems Catapult, the consortium will develop a hybrid vehicle interface (Tevva), a decision-making engine (Dinniq) capable of taking inputs from a range of city data, such as live air quality information (EarthSense) potentially triggering on-demand ZE running instructions (known as active geofencing). The application, markets, business models and scalability of the system will be evaluated by Cenex and the Transport Systems Catapult to inform Leeds and other CAZ cities of the its potential use.
Cities such as London are introducing low or zero emission zones to reduce the socio-environmental impacts of vehicles. Global logistics leader UPS have trialed pure electric vehicles and learned that they are limited on range. If a pure electric delivery vehicle runs low on charge, pulling in to a service station to refuel is not an option . Breakdowns can result in late deliveries and the spoiling of perishable items. In many cases vehicles need a range of at least 60 miles from distribution centres on the edge of town to be able to reach their delivery area in the city and then get back to base. Tevva Trucks’ Range Extended Electric powertrain technology and smart control software achieves this and more. By operating on electric only mode in the city and using a traditional, small car engine running at optimum efficiency to rechanrge its batteries, TevvaDrive constantly optimises performance to deliver both zero emissions in town and a long range. Tevva & UPS have run single vehicle trials successfully for 1 year & need to scale up to fleet wide trials. Tevva & UPS will build & operate 15 of UPS' highly visible, iconic brown P80 delivery trucks across two UK sites, driving daily routes of up to 150 miles to demonstrate the technology’s readiness for mass fleet wide roll out.
The TevvaDrive 2.0 project builds on Tevva Motor's success in pioneering range extended delivery trucks. Working with client UPS in London, Tevva has already shown that a 7.5 tonne truck using a small diesel engine, from a Ford Focus, to charge batteries which in turn provide power to a traction motor, can reduce fuel usage by 50% whilst eliminating harmful tailpipe emissions in cities. This project builds on this success by taking a highly innovative approach to reduce drivetrain cost, making the vehicles cost effecitive to future clients. Tevva will work with Newcastle University whose highly innovate motor and generator design will both charge batteries and drive the wheels; this drive represents unique UK developed technology which eliminates the need for rare earth magnets and complex vehicle cooling systems. Secondly Tevva will work with Vayon in order to make use of batteries from the Nissan Leaf in these trucks; this will dramatically improve the affordability of the truck, take advantage of the high energy density of these batteries (doubling range or halving battery mass) and even allow the use of 'second life' batteries. These second life batteries are those that have through use reached 80% of their orgininal capacity, no longer usable in a car they are still ideal for use in a truck.
TRIUMPH is a demonstration and study of zero emission capable trucks and refrigeration units in urban environments. Refrigerated urban delivery is a key component of the modern food distribution network and temperature controlled transport is highly polluting in urban environments. Zero emission technologies provide a solution to urban air quality and can also reduce CO2 emissions. A limited evidence base exists to support the uptake of new innovative technologies in a commercial vehicle environment. This project will investigate three solutions to zero emission delivery in urban environments. 1) Fully electric vehicles (supplied by Magtec); 2) Range extended electric vehicles (supplied by Tevva). 3) Liquid nitrogen engine refrigeration units (supplied by Dearman). A detailed study of all three options will be undertaken. The project will also: develop real time environmental sensing, provided by EarthSense, which will inform the control strategy of range extended electric vehicles to provide zero emissions operation in areas of the poorest air quality; develop fleet telemetry systems for the trial vehicles; develop fleet advice software to inform roll out in the wider fleet community; and compare the emission, cost and technical performance to Euro VI diesel vehicles.