Public Funding for Danfoss Scotland Limited

Project EPIC is an industrial manufacturing project developing a next-generation integrated electric powertrain (IEPT) for commercial vehicles up to 44 tonne GVW. The consortium comprises Meritor, Danfoss, and Electra. Meritor leads in global axle and drive system engineering, Danfoss develops advanced electric motors, and Electra specialises in electric vehicle integration. The IEPT product will consist of a single motor with an integrated SiC inverter, integral multispeed gearbox and differential, and foundation brakes optimised for regenerative braking. The powertrain will typically suit 4x2 or 6x2 commercial vehicle configurations but other configurations including off-highway, construction and vocational vehicles are also supported. Drive systems exist today with remote mount motors but still rely on drivelines and traditional axles. Existing eAxles rely on two motors to achieve the required torque and power, which adds cost and complexity. The EPIC solution eliminates the driveline and need for multiple motors. Shorter wheelbase EU trucks are especially unable to utilise the area between the frame rails due to the driveline presence, which limits battery storage thereby limiting the vehicle range. With this novel powertrain, the space becomes accessible. The powertrain will share the same chassis mounting as existing axles allowing for easy vehicle application, while its fully integrated nature offers further benefits over remote mount solution including: * Increased storage for batteries and/or hydrogen between frame rails * Approximately 363 kg weight savings * Smaller packaging envelope * High modularity for wide application coverage * Increased range and/or payload * Greater overall efficiency We project to eliminating 4.2 million tonnes of CO2 per year by 2025\. The high efficiency, and reduced weight and space of the powertrain will improve range and/or payload and therefore potentially improving CO2 reduction in a highly criticised sector. The extensive benefits of this new powertrain will equally provide accelerated adoption of battery-electric, fuel cell, and range-extended hybrid commercial vehicles. To deliver the project, Meritor will create a Centre of Excellence in Cwmbran with expanded testing facilities and R&D team. Danfoss will develop and assemble motors with integrated inverters at a Low- Carbon Innovation Centre near Edinburgh. Electra will assemble vehicles with plans to complete durability and field running at U.K. test tracks and on public roads. The vehicles will also be used to demonstrate the technology to major global vehicle manufacturers, fleets, and other potential end users. The total U.K. project expenditure of £82m is projected to create 189 jobs in the U.K. while safeguarding approximately 500\.

"Off-road work vehicles such as excavators, wheel loaders and forklift trucks use hydraulic systems for propulsion and for work functions, such as digging and lifting. The ""analog"" technology of conventional hydraulics suffers from comparatively poor efficiency, and is difficult to interface to computer controls. Pure electric drives however struggle to meet the high forces and powers required at acceptable cost in this tough environment. The industry urgently needs new solutions to deliver the major CO2 reductions demanded by society, at a cost the market will accept. This project aims to introduce to the market a disruptive technology called ""Digital Displacement"", a fundamental re-invention of hydraulic power for the digital age. Combining rugged mechanics with electronics and embedded software, these intelligent machines are digital from the ground up. Energy losses are reduced dramatically, and new efficient system architectures are made possible, enabling energy to be recovered and re-used. This is already proven to lower fuel consumption between 20% and 40%, and has potential for more than 50% reduction when fully developed. Whether machines are powered by engines or electricity in future, it offers the most efficient way to control the high-force multi-axis movements of heavy machinery. These new machines will offer significant operating cost reductions due to reduced fuel consumption and higher productivity, without requiring expensive or rare materials or exotic production processes to manufacture. By developing a family of modular products for UK and global vehicle manufacturers, the project will bring those benefits to a wide range of off-road vehicles. The project combines the technology of UK digital hydraulic pioneer Artemis Intelligent Power, with the experience and scale of Danfoss Power Solutions, one of the world's leading Tier 1 suppliers to the off-road vehicle market. By developing the practical skills needed to deploy and service and this new technology at Robbie Fluid Engineering, a forward-looking small business, and the scientific and technical skills needed to develop it in partnership with the University of Edinburgh, it will position the UK at the centre of a ""digital revolution"" in the off-road vehicle industry."