EM-TECH Simulation results report (D2.4)

The EM-TECH project advances the boundaries of electric machine technology for automotive traction by introducing innovative solutions, including: i) advanced direct and active cooling designs; ii) virtual sensing capabilities for high-fidelity, real-time machine operating condition estimation; iii) improved machine control strategies reducing conservatism, leveraging real-time insights; iv) electric gearing (E-gear) for enhanced operational flexibility and energy efficiency; v) digital twin-based optimization, incorporating Life Cycle Analysis (LCA) and Life Cycle Costing (LCC) considerations from the initial design stages; and vi) the use of recycled permanent magnets and circularity-focused solutions. These innovations enhance radial flux direct-drive in-wheel motors (IWMs for higher torque density levels, and on-board axial flux motors (AFMs) for superior power density. The project aims to deliver cost-effective, energy-efficient technologies with reduced rare earth dependency and integrated magnet recycling for passenger cars, vans, and scalable commercial vehicles. D2.4 is related to T2.4 where comprehensive simulation activities are carried out to assess the vehicle performance improvement resulting from the EM-TECH motor solutions: 1) the modular motor solution is assessed through a wide range of vehicle applications; 2) the high-efficient motor solution is demonstrated from WLTP drive cycle simulation, supported by advanced pulse and glide (PnG) control and brake blending strategy for further energy consumption reduction and also supported by virtual motor temperature sensor; 3) the E-gear IWM solution is evaluated by optimal gear shifting strategies; 4) the rapid-response motor solution is leveraged by an advanced anti-brake system (ABS) and traction control (TC) development. It is demonstrated that the simulation toolchain developed in D2.4 has been instrumental in advancing the EM-TECH project. By enabling the integration, evaluation, and continuous refinement of cutting-edge e-axle and e-corner technologies, the toolchain has provided valuable insights into vehicle-level performance. It effectively assesses the impact of design decisions on energy efficiency, thermal behaviour, and advanced vehicle control strategies, such as pulse-and-glide, ABS, TC, gear-shifting, and virtual sensing techniques, under both WLTP and real-world operation conditions. The toolchain has successfully bridged the gap between component-level development and vehicle-level performance assessment, ensuring alignment with technical requirements and design objectives. Its flexibility in supporting rapid updates and re-parameterisation has been crucial in accommodating advancements from component suppliers, thus promoting strong collaboration among project partners.