Public Funding for Advanced Electric Machines Limited

SIMPLE will establish a route to cost effective manufacturing scale up of traction motor systems through differentiated analysis/simulation and manufacturing process design. By building a pilot line to demonstrate serial production capability it will transform the UK supply chain by delivering a true high volume UK based Tier 1 supplier, driving volume opportunities throughout the supply chain. Focusing on magnet free motor technologies will drive down the cost and environmental impact, removing the inherent cost and high emissions of rare earth materials that are driving many large organisations to identify new solutions. Understanding the key tolerancing effects which drive performance in these magnet free motors and using manufacturing and assembly innovation to maximise these features cost effectively is critical to ensuring adoption. Environmentally, mass adoption of these technologies has the potential to save 133m tonnes of CO2 Equivalents, 300,000 tonnes of radioactive waste and 5m tonnes of landfill being produced each year.

Heavy-duty vehicles account for about 25% of EU road transport CO2 emissions and about 6% of total EU emissions. In line with the Paris Agreement and Green Deal targets, Regulation (EU) 2019/1242 setting CO2 emission standards for HDVs (from August 14, 2019) forces the transition to a seamless integration of zero-emission vehicles into fleets. In line with the European 2050 goals ESCALATE aims to demonstrate high-efficiency zHDV powertrains (up to 10% increase) for long-haul applications that will provide a range of 800 km without refueling/recharging and cover at least 500 km average daily operation (6+ months) in real conditions. ESCALATE will achieve this by following modularity and scalability approach starting from the β-level of hardware and software innovations and aiming to reach the γ-level in the first sprint and eventually the δ-level at the project end through its 2 sprint-V-cycle. ESCALATE is built on the novel concepts around 3 main innovation areas, which are: i) Standardized well-designed, cost effective modular and scalable multipower train components; ii) Fast Fueling & Grid-friendly charging solutions; and iii) Digital Twin (DT) & AI-based management tools considering capacity, availability, speed, and nature of the charging infrastructures as well as the fleet structures. Throughout the project lifetime, 5 pilots, 5 DTs and 5 case studies on TCO (with the target of 10% reduction), together with their environmental performance via TranSensusLCA will be performed. The ultimate goal is to develop well-designed modular building blocks with a TRL7/8 based on business model innovations used for 3 types of zHDVs {b-HDV,f-HDV,r-HDV}. Furthermore, 3 white papers will be produced, one of which will contribute defining the pathway for reducing well-to-wheel GHG emissions from HDVs based on results and policy assessments.

SD-APT brings together diverse organisations with established experience in innovation within the delivery of skills and training and expertise in PEMD to create delivery programs designed to meet the PEMD skills gap challenge at scale. The key objectives will be establishing training assets and routes to: * Transition large volumes of experienced technicians and engineering staff * Prepare a new generation of career-ready PEMD graduates * Engage with a new pipeline of talent The lead partner is Coventry University, a leading modern university with extensive links to transport and major industry sectors. They are joined by North Warwickshire and South Leicestershire College, a large Further Education college working with more than 1,000 national, regional, and local businesses across a wide range of sectors. Resume Foundation, a registered charity, will provide advice and support in working with underrepresented or marginalised people. Industry partners will provide guidance and test training modules to develop content that is refined in a continuous and agile manner to ensure it serves current and emerging sector skills needs. Industry perspectives are represented by industrial end users ZF Automotive UK, GE Power Conversion and supply chain partners Advanced Electronic Machines, Drive System Design and FEV UK. Fluxsys, an SME delivering specialist industrial training, will provide inputs to diversify the type, focus and format of training developed by the project. SD-APT will: * Develop flexible learning assets and supporting content, designed to respond to current and emerging needs of the PEMD sector * Create a blend of state-of-the-art academic and applied industrial teaching materials with a focus upon practical learning * Present core material in a framework which can provide appropriate delivery at skills levels from 2 - 7 * Bring together delivery partners who can tailor the core material framework to meet different student needs through colleges, training institutes and universities, in a range of formats * Creating an agile process whereby the core material can be rapidly adapted to meet industry needs, through digital forums and continuous improvement. * Provide outreach and engagement activities to engage with under-represented groups and with schools to highlight the opportunities in the PEMD and initiate pathways for career development.

The project aims to develop a UK PEMD supply chain that will combine cost effective material supply and cold rolling of a new high strength non-magnetic steel with mass production process innovations that can deliver patented lamination designs. These laminations can then be stacked into novel rotor and stator sub-assemblies to support mass production of more efficient and more sustainable electric machines with wide-ranging application across transport, energy and industrial sectors. The project will focus on the development of material supply and cold rolling processes for cost effective supply of the new high strength non-magnetic steel. Blank forming and joining processes to combine non-magnetic steel with electrical steel will be developed using latest joining technologies. Coating of the patented laminations will use novel insulation/adhesive coating materials, to enable automation of lamination stacking for novel rotor and stator sub-assembly designs supporting mass production of more efficient and more sustainable electric machine designs. In the project the materials and process developments will be applied to the core of a unique AEM electric machine design that will be free of rare earth magnets and copper, validated with prototype motor high speed dynamometer testing. This electric machine design is currently being evaluated by leading global automakers and Tier 1's as a more sustainable electrification solution for mass produced passenger cars. Thereafter the core technologies of the project can be applied to other transport, energy and industrial sectors, providing automotive economies of scale. The partners in the project provide the basis of a 'production ready' UK supply chain with a clear 'end to end' route to market for cost effective materials supply and cold rolling processing, lamination manufacture and rotor/stator sub-assembly, and electric machine production. This project will include production costing and value chain analysis to ensure that this UK supply chain is both market attractive and sustainably profitable.

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.

no public description

RaRE will establish an end to end supply chain for recycled rare-earth ancillary motors. Building on work completed at the University of Birmingham to devise a method to extract magnets from waste electronics the process will be scaled and the material re-processed back into new magnetic materials at pilot scale by Hypromag to demonstrate the quality of material which can be produced in terms of its magnetic behaviour, mechanical performance and corrosion resistance which are key to the end user application. The recycled magnets will be built into an ancillary electric motor designed by Advanced Electric Machines Research to a Bentley Motors specification and focused on reducing the overall complexity of electrical systems in electric vehicles and designed with recycling in mind. This will be the first time that such a recycled motor will have been demonstrated. Unipart will take this motor design and use it as the core focus for the design of a flexible volume motor assembly line suitable for production volumes of 100,000 units p.a.

"OCTOPUS builds on the success of previous Innovate UK project APEX. **Advanced Electric Motors Research** and **The Thinking Pod innovations** will focus optimising the integrated motor and power electronics 'drive' technology and further integrating with a new transmission and thermal management system to deliver the ultimate single unit e-axle solution designed specifically to meet **Bentley Motors** performance specifications. OCTOPUS will use the world class synchrotron and high performance computing systems available from the **Science & Technology Facilities Council** to build new multi-physics modelling solutions and expertise of the **University of Nottingham** to build power electronics modelling solutions and validate them with test data generated by 'looking through' the motor while its running at its maximum operating speed of 30,000rpm. The prototype e-axle, manufactured by **Advanced Electric Machines** at their expanded manufacturing facility in Washington Tyne & Wear, will be tested to OEM Design Verification (DV) standards using the latest testing solutions and test specifications developed using both **University of Bath** and Bentley Motors vast powertrain testing experience, ensuring that it comes out of the project ready to be considered for a vehicle programme. Looking beyond the next generation, OCTOPUS will develop a suite of technologies which target the 2035 Auto Council performance targets by integrating the latest thinking in Additive Manufacturing and nano-material technologies. **Hieta Technologies** will deliver beyond state of the art thermal management and lighweighting solutions in both the motor and transmission while **Talga Resources** UK will develop materials for high performance motor windings delivering an aluminium based solution which will aim to out perform copper. By working on these technologies alongside the core e-axle design, OCTOPUS will aim to accelerate and focus their development with a view to incorporating successful elements into the testing and prototype units, laying the foundations for future design verification programmes. At the end of OCTOPUS the project team will deliver: * **An e-axle prototype** incorporating the latest magnet free motor, wide band gap power electronics and lightweight transmission systems, tested to OEM DV standards using a new test protocol proven on next generation test facilities * **A new multi-physics simulation modelling toolkit** incorporating electromagnetic, mechanical, thermal and NVH solvers operating simultaneously, validated by a never before demonstrated x-ray analysis technique * **Next generation lightweight high performance component systems**, integrating the latest material and manufacturing techniques and tested at component, sub-system and system level and with an integration route into future e-axle designs"

ElecTra brings leading edge UK research in Switched Reluctance Electric Machine design and Vehicle Control Unit development, together with world class mechanical powertrain systems design and integration expertise, and a world leading vehicle manufacturer to deliver a breakthrough in electrification of the agricultural vehicle sector. The electrified powertrain will be designed to deliver differentiated performance and flexibility without the need for both rare-earth magnets and copper windings delivering a package which is both cost effective and recyclable at its end of life The system will be widely applicable across vehicle types and markets with its ability to be easily reconfigured. Working closely with CNH International, Semikron, FD Sims and the University of Bath, Advanced Electric Machines Research, Advanced Electric Machines and SR Technology Innovations will accelerate their technologies towards market readiness while ensuring they are focused on meeting all of the requirements of an OEM design verification plan from the earliest stage of design. Building on world class design capabilities and unsurpassed experience in high volume motor manufacturing, ElecTra will enable UK based suppliers to deliver cost effective prototypes and establish supply chains which can support volume production enabling a market opportunity worth over £500M a year.

.

COALS - COmpressed Coils & Advanced Lamination Solutions

"APEX brings leading edge UK research in power electronics together with ultra-high speed, switched reluctance electric machine design and novel thermal management solutions, to deliver a breakthrough in electric drive systems suitable for high performance vehicles. The drive will be designed to exceed latest permanent magnet motor performance while removing the need for both rare-earth magnets and copper windings -- delivering a package which is both cost effective and recyclable at its end of life and widely applicable across vehicle types and markets. Working closely with Bentley Motors and University of Newcastle, The Thinking Pod Innovations and Advanced Electric Machines Research will accelerate their technologies towards market readiness while ensuring they are focused on meeting all of the requirements of an automotive design verification plan from the earliest stage of design. Building on world class design capabilities and unsurpassed experience in high volume motor manufacturing, APEX will work with UK based suppliers to deliver cost effective prototypes and establish supply chains which can support volume production enabling a market opportunity worth over £525M a year by 2030\."

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.