7 Centuries of Education, Research and Technology Transfer for Excellence

The automotive showcase

Marco Raugi, marco.raugi@unipi.itVice-rector for Reasearch & Technology Transfer, Director of CIRESS,

Full Professor of Electrical Engineering

Massimo Ceraolo, massimo.ceraolo@unipi.itFull Professor of Electrical Engineering

Sergio Saponara, sergio.saponara@unipi.itFull Professor of Electronic Engineering

Past Glories• Galileo Galilei• Antonio Pacinotti (Physics)• Ulisse Dini (Math)

Nobel Prizes & Fields Medals • Giosuè Carducci (Nobel Literature, 1906)• Enrico Fermi (Nobel Physics, 1938)• Carlo Rubbia (Nobel Physics, 1984) • Enrico Bombieri (Fields Medal Math, 1974)• Alessio Figalli (Fields Medal Math, 2018)

Presidents of Republic/Prime Ministers• Carlo Azeglio Ciampi, President of Republic, 1999-2006• Giovanni Gronchi, President of Republic, 1955-1962• Giuliano Amato, Prime Minister, 1992-1993 & 2000-2001• Enrico Letta, Prime Minister, 2013-2014

UNIVERSITY OF PISA

School of Engineering

Piazza dei Miracoli

Leaning Tower (1173) & Cathedral (1063)

UNIVERSITY - HUMAN RESOURCES

• Founded in 1343;• Number of students: ≃ 58000;• Study Programmes:

• First level (3 years): 58 (≃ 31000 st.);• Second level (2 years): 67 (≃ 18000 st.);• 5 years degrees: 8 (≃ 2000 st.);• PhD, Master,...: 34 + 109 (≃ 9000 st.);

• Enrolled st.: ≃ 10000 (1st lv 5300, 2nd lv 3500);• Graduates: ≃ 7000 (1st lv 4500, 2nd lv 2500);• PhD graduates: ≃ 280;• Academic institutions:

• Departments: 20;• Schools: 2 (Eng. and Med.);• Research and teaching staff: 1270;• Technical-administrative staff: 1565;

• 300 Laboratories• Academic Ranking World Universities 2019:

• Top 150-200 Worldwide, Top 1-3 in Italy• QS Automotive related ranking, 5th in Italy

Electrical & Electronic Engineering

Disciplines in :- Electric Machines, Power Converters & Control Units- Mechatronics & Industry 4.0- Energy storage (battery, fuel cells) & energy management - Embedded Systems, IoT & Vehicular Networks - Robotics, AI & Autonomous Driving Systems- Safety & security for vehicles and automotive components

QS RANKING 2019

The University of Pisa has a rich source of innovation within its over 200 labs and 20 departments, which span all areas of science and technology. Since the early 2000s, it started to manage the technology transfer process through a dedicated team composed of experts in intellectual property management and commercialization of research.

TechnologyTransfer

Patenting & Licensing

Spin-offs

• 105 filed Italian patents, of which 81 granted;• 117 filed international patents, of which:• 10 US Patents, of which 7 granted;• 23 European patents, of which 14 granted;.

Spin-offs

• 21 spin-offs approved;• 107 prizes awarded • 13 spin-offs; generated in PhD+ programme.

Best practices &

networks

FINANCED PROJECTS (FP)

AVERAGED YEARLY VALUES

1000 FP; 11.2 MEur

1/3 Competitive Calls2/3 INDUSTRY GRANTS

2 FP each permanent staff member every 3 years

UNIVERSITY – TECH. TRANSFER

UNIVERSITY – PATENTS

Università di Pisa

PD

PI

BO

PoliTO

RM

ENGINEERING - HUMAN RESOURCES

School of Engineering(founded in 1913)

210 profs + 140 post-doc res.

DMDepartment of Mathematics

DFDepartment of Physics

DICIDepartment of Civil andIndustrial Engineering

85 profs + 46 post-doc researc.

• Research area• Aerospace engineering• Civil engineering• Chemical engineering• Mechanical engineering• Nuclear engineering

DESTECDepartment of Energy and

Systems Engineering

50 profs + 27 post-doc researc.

• Research area• Electrical engineering• Energy engineering• Building and structural eng.• Hydraulic, transp., terr. eng.• Management engineering

DIIDepartment of

Information Engineering

75 profs + 67 post-doc researc.

• Research area• Biomedical engineering• Computer engineering• Electronic engineering• Robotics and automat. eng.• Telecommunication eng.

ENGINEERING - EDUCATION

• 12+1 Bachelor Degrees: ≃ 3000 st.• Aerospace engineering;• Biomedical engineering;** max 220 st.• Chemical engineering;• Civil, envir. and building eng.;• Energy engineering;• Electronic engineering;• Management engineering;• Computer engineering;** max 220 st.• Mechanical engineering;** max 220 st.• Telecommunication engineering;• Industrial Design;** max 50 st.• Architecture and Building eng. (5y)

• 19 Master Degrees (2nd level): ≃ 6000 st.• Bionics Engineering*; • Computer Engineering;• Embedded Computing Systems*;• Aerospace engineering;• Biomedical engineering;• Chemical engineering;• Computer engineering;• Electrical engineering;• Electronic engineering;• Energy engineering;• Management engineering;• Mechanical engineering;• Nuclear engineering;• Robotics and automation eng.;• Telecommunication engineering;• Vehicles engineering;• Civil Infrastr. and Environ. eng.;• Structural and Building eng.;• Materials and Nanotechnology;

• 4 PhD Courses: ≃ 200 st.

TEACHING ELECTRIC VEHICLES

Unipi has a Ms Course on Vehicle engineering • Vehicular electronics (6 CFU)• Signal processing and telemetry (6 CFU)• Electric and Hybrid Vehicles (12 CFU)

Teaching of electric and hybrid vehicles, for and half takes place in a laboratory

Higher Education ChallengesFormula SAE Driverless

RoboraceRexus student ESA challenge

Short-Courses for Industry Training (@ industry premises)• Course on Mechatronics for MAGNA • Course on Digital Power Conversion for ABB-Powerone• Course on Power & Control Electronics for Pierburg-Rheinmetall

ENGINEERING - HIGHER EDUCATION

RESEARCH & TECHNOLOGY TRANSFER

Projects at DII (MIUR Excellence Department)25 EU Active Projects (49 in the last 3 years)

5 EU Projects lead by DII faculty members2 ERC Grants10 MIT-UNIPI seed funds23 EU-funded Regional Projects

130+ Projects Commissioned by Companies630+ Collaborations with Companies

Research Units hostedMagneti Marelli STMicroelectronics SIIE (Sino-Italian Information Eng.) CNIT (National consortium for TLC)CNR (National Research Council)CINI (National consortium for computing)

TECHNOLOGY TRANSFER IMPACT

International High-Tech Companies in Pisa Area attracted by High Skilled Engineers & UniPI Tech Transfer Capability:

• Apple (exDialog)• Intel• Continental• Pierburg-Rheinmetall• Magna• Austria Micro Systems (AMS)• Piaggio • Aitronik• Pitom• P2C (PurePowerControl)• Hanking Electronics• Leonardo (Sistemi Dinamici)• Resiltech• Kayser• Kiunsys• NavionicsUNIPI is part of MOVET

PAST AND PRESENT PARTNERS

PAST AND PRESENT PARTNERS

EPI EUROPEAN PROCESSOR INITIATIVE

Safety Critical

Industry 4.0& Robotics

AeroSpace

Automotive

Servers & Cloud

HPCCore

Drivers

sovereignty

AIaccelerators

120M€ in 5 years,26 partners from 10 countriesEPI: the European Processorfor the European AutomotiveIndustry

EPI ROADMAP & ARCHITECTURE

Secure channel

V2V

V2X

EmbeddedHPC

1st EPI chip in 7nm TSMC

BSG FOR HYBRID VEHICLES

Internal CombustionEngine (ICE)

Gearbox

Belt Motor Generator Beltless Motor Generator12V - 48V 48V - 300V

<10kW >10kW

Clutches Wheel

Differential gear

Collaboration with Valeo & AMS in FP7 Athenis3D48 V Belt Starter Generator (up to 15 kW) with Integrated Control Electronics & Power ConvertersTested on a Peugeot 308 Hybrid

• 10+ year experience in BMS design for mid to high power applications• Tuscany region funded projects: Progetto Idrogeno, Prot-One, SUMA• European funded projects: 3Ccar, AutoDrive, NewControl• Company funded projects• National and International collaborations• Tested on real vehicles: Enea Electric BuS, CarbonDream E-bike, GGP Gardening E-tools

AutoDrive

BATTERY MANAGEMENT SYSTEMS

LUTVOC - SOC

+-R0

R1

C1 VOC

1Qn ʃ SOC

+ -L+ -

vT

iL

ParameterIdentification

[R0,R1,C1]

vM

SMART BATTERY & 48V DC/DC

ELECTRIC BUS WITH FAST CHARGE

Charging power (kW)16 17 18 19 20 21 22 23 24 25 26

30

40

50

60

70

80

90

100

110

120

Cha

rgin

g tim

e pe

r km

(s/k

m)

NominalDynamometerRoute 1Route 2Route 3

SOC=70%

SOC=25%SOC=0% 10%

• Advanced Power Drive Control Algorithm (FLC)

Desired TrajectoryFLC ControlPID Control

Extended Kalman Flter (EKF)Sensorless control

Cogging Reduction for high precision apps(Robotics, Automation, Cars)

• HIL Validation on low-cost embedded system

ADVANCED CONTROL OF E-MOTORS

MIT-UNIPI Seed Fund <Power Seed>

ICS FOR SMART SENSE&POWER

SENSIPLUS Sensor platformTemp, radiation, humidity, gases + communication

MEMS Smart sensorsacoustic, thermal, flow

Low cost RFIDReliable and lowcost RFID tags andantennas for WSN

ChiplEss MultisEnsor Rfid for GrEen NeTworks

48 V DC/DC switched-cap converter with 3D passivesFP7 Athenis 3D

MECHATRONIC CO-DESIGN/VERIFICATION

Integrated Environment forCo-design & Co-Verificationof mechanics, control SW &Electronic/Electrical partsin automotive e-drives:The smart latch case study

Robots with AI capabilityDesigned to intervene, as a human, in industry 4.0environments & extreme scenariosSoft-robots for people interaction

ROBOTICS WITH AI CAPABILITY

MARELLI JOINT RESEARCH LAB

Joint Research Laboratory (JRL) started June 2019

• 3-year framework agreement, funded by Marelli year-by-year• Mixed DII – Marelli JRL steering committee• Activity: Cybersecurity Research & Technology Transfer • 2 themes funded for 2019/20 (100 k€ year budget):

Penetration tests & Vulnerability analysis of connected carsAI-enabled Intrusion Detection Systems & ECUs Fingerprinting

• Research Grant for objective: Patent, Innovative Product Development• DII people involved: 2 professors, 3 PhDs, 4 Master Thesis Students

SIIE (Sino Italian Information Engineering) Joint Research Lab started Dec 2017• Activity: Research & Higher Education• 1.2 M€ initial budgetMain research themes• Electronics & Nanotechnology • AI & Robotics• Electromagnetic scattering and radiation, AntennasChinese partners involved:• Beijing Institute of Space LM Vehicle (part of China Aerospace Science and

Technology Corporation)• Beijing Institute of Technology (BIT) PhD double degree

• Program 111 with Xidian University, Xi’an

• DII lab hosting 10 Chinese PhDs in 2 years, funds by China Scholarship Council

SIIE JOINT RESEARCH LAB

AUTOMOTIVE RELATED RESEARCH

Numerical and analytical methods:

● Integral and Hybrid FEM/MOM formulations;● Equivalent Network formulations;

● FEM analysis of EM devices: Effe, Ansys, Magnet, Comsol● Fourier/Bessel analytical methods;

● GPU-accelerated formulations;● 6DoF electromechanical coupled formulations.

Electromagnetic compatibility:

● Advanced Transmission Lines Modelling;● Crosstalk Evaluation;

● Statistical analysis of systems with uncertain parameters and cable bundles;

● High Speed Interconnects identification;● Sensitivity analysis of complex interconnects.

AUTOMOTIVE RELATED RESEARCH

Large Machines

Innovative Machines

Induction and PM ASI-Nidec

Macro-Topics:•Electric Machines•Power Electronics•Electrical Drives and ApplicationsActivities:•Theoretical modeling and analysis•Numerical modeling and Simulation•Design and Experimentation

Small Machines

Axial flux variable

reluctance

Rotary-linear Brushless

DC hybrid excitation

Synchronous Ansaldo Energia

~1 PM Alternators Axis-EU

Automotive actuators Magna

Brushlessconsequent

pole

Mains extender

Power Electronics Heaters regulators

Modulation techniques

Active Filters Uni Nottingham

0.26 0.27 0.28 0.29 0.3 0.31 0.32 0.33 0.34

-1

-0.5

0

0.5

1

t [s]

vkik

[pu]

AUTOMOTIVE RELATED RESEARCH

Drive for Hybrid electric vehicle

Traction motor:IPM BrushlessPn = 40 kW

Direc drive brushless for mix concrete

Hybrid working machinesDrive for Hybrid electric vehicleTraction motor: IPM Brushless

This IPM motor was designed from scratch

to match requirements of a vehicle prototype (Piaggio Porter)

ELECTRIFIED RAIL

• Hybrid electro-mechanical modelling of trains together with feeding systems

• Evaluated effectiveness of stationary storage to enhance energy efficiency

• Collaboration with Trasporti Elettrificati Bergamo (company that manages bergamo tramways)

• Electro-mechanical evaluation of 2x25 kV Railway feeding systems

• Collaboration with Università di Roma and Italcertifer

ELECTROCHEMICAL STORAGE

We test individual cells and modules, up to 60V - 500 A, within thermal changer operating between -40 and +180°C.

What we did:

1. We tested several types of cells and supercaps, in collaboration with ENEA

2. We used tests to develop reliable battery models

3. We use model to develop State-of-Charge evaluation algorithms.

4. During 2019 we tested cells on behalf of CassioliGroup, which is evaluating changing their batteries for in-storehouse vehicles as a consequence of our tests.

5. We are currently testing batteries for Toyota Material Handling Italia, which wants to enhance their electric and hybrid front-end loaders

ELECTROCHEMICAL STORAGE

30-h, 45 NEDC tests, with automatic

charge balancing(based on OCV-SOC

correlation)

(f ile nedc.mat; x-v ar t) i 0 200 400 600 800 1000 1200 -50

-25

0

25

50 [A]

(f ile 6C_sy mm_mult.mat; x-v ar x) T_batt T_amb 0 200 400 600 800 1000 1200[s]

20

25

30

Current (A)

temperatures (°C) Battery case

Room t (s)

t (s) Temperature-rise based stress evaluation

We were able to test the equivalent of several thousand kilometres; the result was that the batteries were able to withstand much higher pulse-charging currents than the very manufacturer knew!

ELECTROCHEMICAL STORAGE

According to our studies two installations were built:• A 1MWh battery and VSC to perform active and reactive power-based grid

services in a location near Pisa (collaboration with EEI - EquipaggiamentiElettronici Industriali)

• A system installed in Bergamo railway to recover braking energy• Our series-hybrid fuel-cell based vehicle's battery

HYBRID VEHICLES

driverrequests

bus DCFuel

EPC EPC

Power Management Module (PMM)

PEGS PED

PRESS

EGS

ESS

mechanicalpower

primary converter electric drive

EMPAUX

AUX

PU

PEGS*? s*

TED*

SOCON/OFF

EGS = Electricity Generator System EPC = Electronic Power Conditioner EM = Electrical Machine ESS = Energy Storage System

driverrequests

bus DCFuel

EPC EPC

Power Management Module (PMM)

PEGS PED

PRESS

EGS

ESS

mechanicalpower

primary converter electric drive

EMPAUX

AUX

PU

PEGS*? s*

TED*

SOCON/OFF

EGS = Electricity Generator System EPC = Electronic Power Conditioner EM = Electrical Machine ESS = Energy Storage System

Fuel

EPC EPC

Power Management Module (PMM)

PEGS PED

PRESS

EGS

ESS

mechanicalpower

primary converter electric drive

EMPAUX

AUX

PU

PEGS*? s*

TED*

SOCON/OFF

EGS = Electricity Generator System EPC = Electronic Power Conditioner EM = Electrical Machine ESS = Energy Storage SystemEGS = Electricity Generator System EPC = Electronic Power Conditioner EM = Electrical Machine ESS = Energy Storage System

Modeling and design of hybrid vehicles

Fuel (and emission) optimisation

algorithm

Load forecast

Driver input interpretation

HighNormalLow

PEGS*? s* SOC

ON/OFF PU

Ppaf

SOC*

driverrequests

driverlong-termintention

other signals

TED*

PMM

Fuel (and emission) optimisation

algorithm

Load forecast

Driver input interpretation

HighNormalLow

PEGS*? s* SOC

ON/OFF PU

Ppaf

SOC*

driverrequests

driverlong-termintention

other signals

TED*

PMM

600 700 800 900 1000 1100 1200-30

-20

-10

0

10

20

30

time (s)

pow

er (k

W)

RESS ED FCSPEGS(t) PESS(t) PU(t)

600 700 800 900 1000 1100 1200-30

-20

-10

0

10

20

30

time (s)

pow

er (k

W)

RESS ED FCSPEGS(t) PESS(t) PU(t)

6 00 7 00 80 0 900 10 00 1100 12000

40

80

tim e (s)

spee

d (k

m/h

)

The department owns a specific capability of simulating hybrid vehicle power trains, to define optimal control strategies.This capability has been exploited in several funded projects (next slide)

HYBRID VEHICLES

ICE CVT R CC

OO, TVA dashboard

EMS (PMM) driver

p*

EPC

EM

oo, ω i

BS GHP OM

V, I, θ ωr

Internal Combustion Engine ICE

Continuously-variable Transmission CVT

Centrifugal clutch CC

Electric Machine EM

Electronic Power Converter EPC

Reduction Gear R

Energy Management System EMS

OO: engine on-off signalTVA: throttle valve apertureBS: braking signalGHP:gas handle positionOM: operating modeP*: controlled electrical poweroo: on/off state of ICEωi, ωr: angular speedsV, I, θ: battery voltage, current, temperature

36

The concept and architecture (UNIPI)

HYBRID VEHICLES

A study (By Piaggio) for the final realisation

The first working prototype of the hybrid power train

Physical realizations

The real thing! (Piaggio)

The whole project was a successful collaboration between Unipi and Piaggio.

HYBRID VEHICLES

A study was carried out in the framework of Industria 2015 project in conjunction with BredaMenariniBus.The study, for its hybrid vehicle part, aimed at defining, through simulations, the vehicle architecture, control strategy, component size. The bus was then built and tested by BredaMenariniBus

A study was carried out around 2010 to create a hybrid fuel-cell vehicle. The main purpose was to locate all components below the vehicle floor, so that no space penalty was introduced in comparison with the existing commercial version.Funded by Regione ToscanaThe vehicle was successfully built and tested.

Physical realizations

FUEL-CELL VEHICLES

FUEL-CELL VEHICLES

Everything is below the floor: mission complete!

MULTI-PHYSICS

It also collaborates with Open-Source Modelica Consortium* to improve simulation tools and libraries.

*www.openmodelica.org

Here a hybrid vehicles is simulates in its three four layers: driver, Energy management system, power train, vehicular (longitudinal) mechanics. It involves control, mechanical and electrical parts

Simulation of vehicles requires simulating interaction among different engineering systems: electric, electronic, mechanic, thermal control, fluids.Conventional simulation tools have limitations in doing this.Multi-physics Cyber-physical simulation allows overcoming these limitations and difficulties.

Destec excels in using Modelica language for cyper-physical, multi engineering simulations

WHAT'S NEXT

There is a tough discussion on the real environmental friendliness of electric vehicles.The best approach is a Life-Cycle Assessment, and, for the useful life-part, well-to-wheels analysis.

• Professional studies show a good edge for the battery electric vehicles• Fuel-cell vehicles are somewhat intermediate between battery electric and

conventional ones, but they may be useful to diversify• More studies are needed: most approaches, for instance, consider the pollution

induced by electricity consumption without considering the time of the day, which can distort things dramatically

7 Centuries of Education, Research and Technology Transfer for Excellence

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