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RESOLVE – Range of Electric Solutions for Lcategory Vehicles

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EGVIA - ERTRAC 1st European Conference Results from Road Transport Research in H2020 projects
29 November 2017 to 30 November 2017
Brussels

Published in: Automotive
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RESOLVE – Range of Electric Solutions for Lcategory Vehicles

  1. 1. This project has received funding from the [European Union’s Horizon 2020 research and innovation programme under grant agreement No 653511 Marco Pieve Piaggio & C. SpA
  2. 2. This project has received funding from the [European Union’s Horizon 2020 research and innovation programme under grant agreement No 653511 RESOLVE Agenda § Concept, Barriers, Objectives and Strategies § Technical achievements § What customers ask for 2
  3. 3. This project has received funding from the [European Union’s Horizon 2020 research and innovation programme under grant agreement No 653511 RESOLVE Project § Project full title: Range of Electric SOlutions for L-category VEhicles § EC Call: H2020 - GV.5-2014 - Electric two-wheelers and new light vehicle concepts § Contract Number: n° 653511 § Project Start Date: 01.05.2015 § Duration: 36 Months § Project costs: 6,92 M€ § EU Contribution: 6,92 M€ § Project Coordinator: Piaggio & C. S.p.A. § Project Officer: Georgios Charalampous 3
  4. 4. This project has received funding from the [European Union’s Horizon 2020 research and innovation programme under grant agreement No 653511 § AIT (A) § IDIADA (SP) § Bosch (D) § KISKA (A) § KTM (A) § MARELLI (IT) § Piaggio (IT) - coordinator § RE:Lab (IT) § Ricardo (D) § University of Firenze (IT) § University of Pisa (IT) § University of Prague (CZ) § University of Warwick (UK) § Wamtechnik (PL) Consortium § A strong and well-balanced Consortium made of 14 partners: 4
  5. 5. This project has received funding from the [European Union’s Horizon 2020 research and innovation programme under grant agreement No 653511 Project Background § Future mobility scenarios for EU urban areas see a modal shift in personal mobility from family cars to lighter, smaller and more environmentally friendly alternatives1. § Besides walking and cycling, these alternatives include a range of L- category vehicles (LVs) — with a growing share of electric. § Urban policies should encourage Electric LVs adoption; particularly, four limiting factors are slowing down the diffusion of ELVs: cost, energy efficiency, attractiveness and riders willingness to use. 1 cfr. White Paper on Transport 2011 par. 2.4.32: “The use of smaller, lighter and more specialised road passenger vehicles must be encouraged” 5
  6. 6. This project has received funding from the [European Union’s Horizon 2020 research and innovation programme under grant agreement No 653511 Concept, Barriers, Objectives and Strategies Limiting factors of ELV widespread adoption Cost Attractiveness in urban areas Willingness to use Develop a range of electric powertrain Demonstrate through two tilting 4- wheelers prototypes Improve rider experience Increasing willingness to use of ELVs RESOLVE CONCEPT: making Electric LVs practical alternatives to cars Objectives Policy factors Energy Efficiency 6
  7. 7. This project has received funding from the [European Union’s Horizon 2020 research and innovation programme under grant agreement No 653511 RESOLVE advances in a nutshell Demonstrated on tilting 4-wheelers concepts ready to be applied to a wide RANGE of LV-Types Common approach to design and simulation Synergies on components Long term vision 7
  8. 8. This project has received funding from the [European Union’s Horizon 2020 research and innovation programme under grant agreement No 653511 #1: To develop an integrated, scalable, modular range of fully electric LV drivetrains… § Modularity § Economies of scale, flexibility § Scalability § Same hardware, ad-hoc reconfigurable software § Functional integration (all-in-one) § Reduction of design complexity and number of components § Use of SotA low-cost solutions § Cost reduction due to economies of scale 8 …that will have marginal unit manufacturing costs of not more than €300 (4kW drivetrain), for a design volume of 10,000 per year
  9. 9. This project has received funding from the [European Union’s Horizon 2020 research and innovation programme under grant agreement No 653511 Modularity: Battery Pack § A universal 48V module 12S4P allows for realizing different battery packs (shape, volume and capacity) Vehicle demonstrators D1 D2 Cell type Li-Ion 18650 Module 12S4P (518 Wh) Number of modules 2 x 3 modules 1 x 8 modules Operating Voltage Range 30 – 50,4 Vdc Battery Nominal Energy 3,11 kWh 4,14 kWh Weight (approx.) 2 x 10kg ~ 22 kg Dimensions L/W/H [mm] 300 x 258 x 76 368 x 258 x 76 Charge current 20 ADC 40 ADC Discharge current 80 ADC cont. 100 A peak (per battery pack) 140 ADC cont. 200 A peak Operating temperature disch. -20 – +60 °C D1 battery pack – 2 x 3 modules, ~3 kWh (2 swappable batteries) D2 battery pack – 8 modules, ~4 kWh (structural function) 9
  10. 10. This project has received funding from the [European Union’s Horizon 2020 research and innovation programme under grant agreement No 653511 Scalability and functional integration: DMM § Integration of electric vehicle functions in a single scalable hw component § Ad-hoc software development (know-how) 10 Functionalities DC/DC Converter Inverter Control Unit Battery charger CAN communication DMM specification of inverter Range DC Input 27 - 56 V DC Max. Power output (peak) 4 kW Max. revolution speed 12’000 rpm Drivetrain Management Module (DMM)
  11. 11. This project has received funding from the [European Union’s Horizon 2020 research and innovation programme under grant agreement No 653511 Use of SotA low-cost solutions § Technology transfer and adaptation of solutions already developed in automotive field 11 E-motor Inverter E-motor Inverter • Three phase brushless internal permanent magnet motor • Transmission gearing integrated • Motor electrically excited synchronous machine with claw pole rotor and additional ferrite magnets • Power electronic unit integrated D1 D2
  12. 12. This project has received funding from the [European Union’s Horizon 2020 research and innovation programme under grant agreement No 653511 #2: To showcase advances to State-of-the-Art (SotA) in two tilting four-wheelers demonstrators… 12 …belonging to L2e and L6e categories, with energy efficiencies of 35 Wh/km and 41 Wh/km on a realistic urban journey profile Specifications D1 D2 Vehicle curb weight [kg] 200 250 Battery weight [Kg] 25 28 On board energy [kWh] 3,1 4,1 Max cont. Power [kW] 4 6 Max width [mm] 754 1184 Max length [mm] 1900 2287 Wheelbase [mm] 1300 1719 Seat height [mm] 800 724 Front track [mm] 466 707 Rear track [mm] 370 440 Max lean angle [°] 36 45 Roll lock system Manual Autom. D1 - L2e category (three-wheel moped) 4 kW – 45 km/h D2 - L6e category (light quadricycle) 6 kW – 45 km/h
  13. 13. This project has received funding from the [European Union’s Horizon 2020 research and innovation programme under grant agreement No 653511 Energy efficiency: predicted performances D1 - L2e D2 - L6e Top speed [km/h] Limited to 45 km/h Acceleration 0 – 45 km/h [s] 3,1 4,6 Energy consumption WMTC [kWh/100km] 3,9 5,2 Range WMTC [km] 105* 81* Range NEDC [km] 103* 80* *Calculation made with battery capacity 4,14 kWh for both vehicles Scooter 125cc:~4 sec Twizy:~6,1 sec Twizy: 90 km (declared) Battery 6,1 kWh WMTC driving cycle operating points D2 D1 13
  14. 14. This project has received funding from the [European Union’s Horizon 2020 research and innovation programme under grant agreement No 653511 #3: To improve the driver experience of ELVs. …developing a multi-wheel vehicle control algorithm that will improve handling/stability and HMI improvements that address range anxiety… l INCREASE RANGE by Regenerative Braking – Driver should not perceive any difference between regenerative and “non-regenerative” deceleration l REDUCE RANGE ANXIETY by Smart Range Management – Driver should feel safe and confident that the final destination can be reached within the given battery charge l IMPROVE DYNAMIC SAFETY by Stability Control – dynamic behaviour similar to PTW but safety increased with two tires for each axle with a dedicated vehicle control 14
  15. 15. This project has received funding from the [European Union’s Horizon 2020 research and innovation programme under grant agreement No 653511 #3: Make rider safe and comfortable: HMI § ad-hoc controls enabling the rider to have a safer, highly ergonomic and effective interaction with the vehicle § real time helpful information issued to improve ELV efficiency and rider comfort § Smart Range Management § Regenerative Braking 15 On board TFT Display smartphone APP
  16. 16. This project has received funding from the [European Union’s Horizon 2020 research and innovation programme under grant agreement No 653511 #4: To make ELVs more attractive to car drivers… 16 resulting in an increase in the percentage of car drivers that consider LVs as a viable alternative to their cars for their urban travel needs. § Attractive vehicles taking into account User Needs
  17. 17. This project has received funding from the [European Union’s Horizon 2020 research and innovation programme under grant agreement No 653511 Willingness to use is not just a matter of attractive vehicles § Cost: electric scooter is expected to have a purchasing price comparable to a conventional ICE (mostly 50cc), § Range autonomy in real driving situation is always expected more than 60km; § Convenience and easy of use rather than the aesthetics are key purchasing factors, even if constrained by current limited offer. § Quality: customer pays attention to the brand, especially at technical parts (i.e. engine and battery) 17 Alternative strategies and business models to be explored
  18. 18. This project has received funding from the [European Union’s Horizon 2020 research and innovation programme under grant agreement No 653511 Next steps § In-lab and track tests to assess performances and targets resulting from simulation § Acceptability tests and user survey ex-post to assess attractiveness of RESOLVE concepts § Refinement of cost analysis and market analysis to look for Business Model Innovation 18
  19. 19. This project has received funding from the [European Union’s Horizon 2020 research and innovation programme under grant agreement No 653511 Main achievements vs. objectives 19 Indicator Units used Project reference Project objective Current achievements Types of vehicles Overall vehicle energy efficiency improvement [Wh/km] Smart Range Management, regenerative braking Energy consumption in real driving conditions 35 Wh/km (D1); 41 Wh/km (D2) Simulations indicated values slightly higher considering ideal conditions. Realistic targets to be assessed after test are: 45 Wh/km (D1); 54 Wh/km (D2) L-category Vehicle weight reduction [kg] or % Reduce vehicle weight by reducing weight of battery and optimal weight distribution 15% comparing to similar priced vehicle. Weight (including driver) targets D1 - 225 kg; D2 – 325 kg D1 about 275 kg, D2 about 350 kg - estimated weight from virtual mock-up and realized components L-category Demonstrator developed Full electric vehicles 2 tilting four-wheelers L2e, L6e category 3 tilting (2 four-wheelers and 1 three wheeler) L-category Cost reduction through functional integration [€] Modularity and generic powertrain simulation model to enable scalability; Functional integration to reduce complexity; Integrated, scalable, modular range of fully electric LV drivetrains will have marginal unit manufacturing costs of not more than €300 (4kW drivetrain), for a design volume of 10,000 per year 4kW drivetrain management module (DMM) is expected to cost €500 for 2000 volume per year L-category
  20. 20. This project has received funding from the [European Union’s Horizon 2020 research and innovation programme under grant agreement No 653511 Thank you for attention www.resolve-project.eu 20

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