RESOLVE – Range of Electric Solutions for Lcategory Vehicles

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

RESOLVE Agenda
§ Concept, Barriers, Objectives and Strategies
§ Technical achievements
§ What customers ask for
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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
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§ 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:
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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”
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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

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

#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
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…that will have marginal unit manufacturing costs of not more than
€300 (4kW drivetrain), for a design volume of 10,000 per year

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)
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Scalability and functional integration: DMM
§ Integration of electric vehicle functions in a single scalable
hw component
§ Ad-hoc software development (know-how)
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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)

Use of SotA low-cost solutions
§ Technology transfer and adaptation of solutions already
developed in automotive field
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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

#2: To showcase advances to State-of-the-Art (SotA) in two
tilting four-wheelers demonstrators…
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…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

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
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#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
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#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
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On board TFT Display
smartphone APP

#4: To make ELVs more attractive to car drivers…
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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

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)
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Alternative strategies and
business models to be
explored

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
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Main achievements vs. objectives
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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

Thank you for attention
www.resolve-project.eu
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RESOLVE – Range of Electric Solutions for Lcategory Vehicles

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