Conceptual Design and Regulatory Framework of a Modular Electric Propulsion System for Urban and Industrial Vehicles

The electrification of urban and industrial transport is driving the need for propulsion architectures that combine energy efficiency, operational flexibility and regulatory compliance. However, current electric platforms often lack the adaptability required for customized body configurations and multistage manufacturing, and their approval is hindered by the complexity of meeting electrical safety and electromagnetic compatibility (EMC) requirements at vehicle level. This article presents the conceptual design of a modular electric propulsion module developed within the MODULe project, in which the traction motor, inverter, battery pack, Battery Management System (BMS) and cooling circuits are integrated into a standardized module conceived as an Independent Technical Unit (ITU). The propulsion module dimensioned using a modified WLTP cycle, and the results indicate that the selected components can meet the dynamic demands of light and medium-duty vehicles, achieving an estimated consumption of around 50 kWh/100 km and a driving range above 160 km. By concentrating the critical regulatory requirements within a single module, the proposed architecture facilitates multistage vehicle approval, reduces development effort and supports the scalable electrification of commercial fleets. This approach may contribute to accelerating the deployment of zero-emission vehicles in urban logistics and industrial applications, with potential benefits for both the sector and society.