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.
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.
"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\."