Low Carbon Vehicle Technology Project compelling advantages that road vehicles enjoy over other forms of land transport; convenience, affordability, comfort and enjoyment, and which

Low Carbon VehicleTechnology Project

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ContentsForeword 3

Introduction to the Low Carbon Vehicle Technology Project 4

Partners 4

Batteries and Battery Packs 6

Drive Motors 7

Power Electronics 8

High Voltage Electrical Distribution Systems 9

Auxiliary Power Units 10

Vehicle Supervisory Control 11

Lightweight Structures 12

Key Technology Achievements 14

Aerodynamic Performance 16

HVAC and System Cooling 18

Reduction of Parasitic Losses 20

Waste Energy Recovery and Alternative Energy Storage 21

Vehicle Dynamics and Traction Control 22

Human-Machine Interface Engineering 23

Vehicle Integration and Validator Platforms 24

Key Contacts 26

02

ForewordThe task facing automotive designers in reducing CO2 emissions from a new car fleet average of 160 gm/km to 40 gm/km in the space of a little over two decades is stimulating some of the biggest technological changes the industry has ever seen.

Engineers must invent technologies that continue to deliver all the compelling advantages that road vehicles enjoy over other forms of land transport; convenience, affordability, comfort and

enjoyment, and which have resulted in them enjoying 90% market share for decades. The cars of the future have to be desirable as well as incredibly efficient.

These changes mean huge opportunities for companies who can offer the best solutions, and will also open up opportunities for newcomers as the incumbents’ established advantages are at least partly eroded by the scale of technological change. This includes companies operating here in the UK, where the automotive sector has enjoyed something of a renaissance in recent years, and where collaboration between government and industry has resulted in a focused drive to position the UK as one of the leading nations where the development of new, low carbon, automotive technologies and businesses can flourish. The action plan spans many complementary initiatives, and the Low Carbon Vehicle Technology Project is one of the most important and most successful.

It has brought together high quality partners from industry and academia to concentrate and accelerate a range of technological developments that help answer key questions about the best ways of increasing the electrical content of the primary and secondary power functions of the vehicle, and crucially, has not overlooked the tertiary issues such as parasitic losses, climate control and dynamics, which are all impacted and provide further opportunities for efficient innovation.

The results of the project speak for themselves: a rich legacy of ideas and solutions, implementable devices and development tools, and a much enhanced body of knowledge here in the UK which is powering our existing investors forward into the low carbon era, and has the power to increase the attractiveness of the UK to new investors.

Professor Richard Parry–Jones CBE Co-Chair, Automotive Council UK

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Introduction to the Low Carbon Vehicle Technology ProjectThe Low Carbon Vehicle Technology Project (LCVTP) is a major collaboration between leading automotive companies and research partners aimed at revolutionising the way low carbon vehicles, including full battery vehicles and hybrid vehicles, are designed and developed in order to significantly reduce carbon emissions.

The £29m project, funded by Advantage West Midlands, the European Regional Development Fund and contribution from industry partners, brings together world class UK OEMs, consultancies, suppliers and academic institutions into a focused collaborative programme to create the required R&D capability and capacity for the development of key low and ultra-low carbon vehicle technologies.

The project partners have also worked with other West Midlands industrial and academic institutions, including a significant number of local Small and Medium Enterprises (SMEs) in order to deliver socio-economic improvements such as improved technical skills, business capability and new products and processes.

The project aims to accelerate the research and development of the first low carbon vehicles by four years and to safeguard over 2,000 jobs in the region’s automotive supply chain as businesses embrace low carbon opportunities. It is pivotal to the government’s decision to declare the West Midlands a Low Carbon Economic Area for advanced automotive engineering and in making the West Midlands a global centre of excellence in low carbon vehicle engineering.

Here we highlight the achievements of the active R&D phase of the project and the business impacts that are now being felt through embedding of the research outcomes.

John O’Connor Project Director

Coventry University

Coventry University is a modern, forward-looking university whose roots can be traced back to 1843 to the Coventry College of Design. With a proud tradition as a provider of high quality education, a focus on multi-disciplinary applied research and links with leading-edge businesses in a variety of industries, today the University has established an academic presence regionally, nationally and across the world. Its globally-renowned automotive design courses regularly produce graduates who go on to leading positions in the industry, and its vehicle engineering expertise is helping to establish it as a recognised centre of excellence in research and practice within the field of low carbon transport.

Jaguar Land Rover

Jaguar Land Rover (JLR) is the UK’s largest automotive manufacturing business, built around two iconic British car brands with a wonderfully rich heritage and incredibly powerful consumer appeal and loyalty. As the UK’s largest investor in automotive R&D and engineering, committing over £1.5 billion a year to product creation, JLR is at the centre of the UK automotive industry’s drive to deliver technical innovation in all areas of vehicle development. As the UK’s largest automotive employer, JLR has a world class team of 20,000 people in the UK, plus 1,000 globally. In addition it supports 140,000 people through the supply chain, dealer network and wider economy.

MIRA Ltd

MIRA is a world class whole vehicle engineering and consultancy company, with a global reputation for innovation, testing and design. With 65 years of rich engineering heritage, MIRA hosts a core of over 500 industry experts, 90km of specialised proving ground and over 30 major test facilities. This unique offering allows its dedicated staff to carry out an array of advanced modelling and simulation techniques within the same location, enabling MIRA to provide smarter solutions to customers’ challenging problems. With over a decade of experience in the field, MIRA continues to lead the way in low carbon vehicle engineering and design.

Ricardo plc

Ricardo plc is a global, world class, multi-industry consultancy for engineering, technology, project innovation and strategy. With almost a century of delivering value, it employs over 1,600 professional engineers, consultants and staff. Its people are committed to providing outstanding value through quality engineering solutions focused on high efficiency, low emission, class-leading product innovation and robust strategic implementation. Ricardo’s client list includes the world’s major transportation original equipment manufacturers, supply chain organisations, energy companies, financial institutions and governments. Guided by corporate values of respect, integrity, creativity and innovation and passion, Ricardo enables its customers to achieve sustainable growth and commercial success.

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Tata Motors European Technical Centre plc

Tata Motors European Technical Centre plc (TMETC) is a wholly-owned subsidiary of Tata Motors Ltd. Created in 2005, as a UK-based centre of excellence for automotive engineering, TMETC provides research and development principally for Tata Motors but also for selected partners in the automotive industry. More specifically, TMETC has expertise in product design and styling, electric and hybrid vehicle technology, body and trim engineering, craftsmanship, systems integration and refinement, electrical and electronic systems design and development, automated transmissions, vehicle dynamics, vehicle testing and homologation, programme management and launch support, as well as manufacturing engineering and pilot production/assembly of low carbon vehicles.

WMG

An academic department at the University of Warwick, WMG has been an international role model for how universities and business can successfully work together for over 30 years. It is at the forefront of innovative technology, leading major multi-partner projects to develop new processes and products which have huge benefit to UK organisations. These projects have seen WMG working across sectors including automotive, aerospace and defence, digital, healthcare and rail. World renowned for providing high quality education programmes, with the latest innovative subjects that meet business and industry needs, WMG continually adapts courses to ensure they meet academic standards and provide companies with individuals who will become future leaders.

Zytek Automotive

Zytek Automotive is a specialist powertrain and vehicle engineering company dedicated to delivering exceptional value to its clients with innovative engineering solutions. Building on its expertise in the development of engine management control systems, Zytek Automotive is now designing and manufacturing electric and hybrid powertrains and ancillary components for many of the leading vehicle manufacturers, where it has demonstrable experience and a proven track record in solving complex engineering challenges for production vehicle projects. Zytek Automotive’s success can be attributed to its highly skilled and committed workforce, its comprehensive in-house test and development facilities, and its electronics and electric traction motor production facilities – a feature unique to Zytek amongst automotive design consultancies.

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Batteries and Battery Packs The development of high performance battery modules, packs and cells continues to be a priority for the next generation of low carbon vehicles. To this end we have developed a suite of tools for appraising and designing new battery systems and related hardware, greatly reducing R&D lead times.

Achievements include:

• Innovative design concepts for battery modules and battery packs

• New testing methodologies for appraising battery cells and modules

• A comprehensive database of commercially available battery products

• An integrated computer simulation model with the capability to predict battery performance characteristics in a wide range of vehicle applications

• A new library of finite element models enabling structural and safety analysis of battery modules and battery packs

• A validated lower-cost Battery Management System (BMS) concept utilising new algorithms for energy balancing and new hardware

• Guidelines to improve design-for-assembly aspects of battery modules

• Guidelines for the recycling of battery products to reduce their overall carbon footprint

• An advanced battery cycler capable of replicating harsh operating environments

Business Impact – New Products and Processes

Tata Motors European Technical Centre (TMETC) has developed a flexible, scalable module suitable to produce battery packs for each of the target Generic Technology Validator (GTV) platforms. This module has been fully validated during the programme and design iterations have been established.

Based on a reduced electrochemical approach, TMETC has also developed a brand new process to model the heat generated from batteries for any drive cycle using estimated voltage. This has been validated for a tested load cycle, and is being utilised by TMETC in the design of state of the art BMS and predictive vehicle drive cycle models.

Ricardo has developed new analysis techniques for determining the physical strength of battery modules and their components in resisting both normal and abuse case loads. These new techniques will be an important addition to Ricardo’s engineering services portfolio.

Given the extensive range of battery cell technologies and suppliers, one of the key challenges facing the industrial partners is selection of the most suitable cells for their specific applications. To support this, WMG has built a new state of the art lithium ion battery testing facility allowing performance and characterisation testing of a variety of battery cell technologies.

Lead Partner

Tata Motors European Technical Centre (TMETC)

Supporting Expertise

Cranfield University, Jaguar Land Rover, Ricardo, University of Glamorgan, WMG

06

Drive Motors Electric and hybrid vehicles demand efficient, torque and power dense, and low-cost drive motors. Project research encompassed several key areas relating to drive motors including: a review of state of the art traction motor technology, an assessment of vehicle drivetrain architectures, a comparison of typical OEM requirements for traction motors and an investigation into techniques for simplifying the process of selecting a traction motor for a particular vehicle application.


• Development of a motor selection tool that evaluates various vehicle performance requirements and other criteria and computes the power and torque requirements for suitable traction motors

• Design of a searchable database of commercially available traction motors that may be used to compare different manufacturers’ machines satisfying specific criteria

• A review of OEM, safety and legislative standards specifically relating to traction motors

• Design, development and manufacture of a concept external rotor starter-generator machine, designed for integration with a small IC engine for vehicle Auxiliary Power Unit (APU) applications

• Design, development and manufacture of a concept high-power, high-torque traction machine for performance vehicle applications

• An analysis of traction motor designs used in current hybrid and electric vehicles based on product teardown


The Motor Selection Tool (MST) is already proving valuable to engineers at Jaguar Land Rover, MIRA, Ricardo, Tata Motors European Technical Centre (TMETC) and Zytek Automotive. The user is prompted to specify a range of vehicle performance criteria which are then used to compute motor torque and power requirements. As an additional feature, the MST provides links into a large database of commercially-available machines and makes recommendations of suitable ‘best-fit’ off the shelf products. A further benefit is the support for conducting ‘what if’ scenario analyses in order to quickly identify an optimal motor solution for a particular application. This process is usually lengthy and labour intensive, requiring highly skilled personnel. Using the MST therefore provides significant commercial benefits.

Ricardo and Zytek have designed, developed, manufactured and tested an external-rotor starter-generator concept which is intended for use with a production combustion engine to create a compact APU or range extender. The design activity included full integration of the starter-generator with the combustion engine to achieve a compact yet weight-efficient system negating the need for a flexible coupling.

Lead Partner

Zytek Automotive


Jaguar Land Rover, MIRA, Ricardo, Tata Motors European Technical Centre (TMETC), WMG

07

Power ElectronicsRobust and efficient power electronics with high power densities are an essential enabling technology for low carbon vehicles. Our research has focused on fundamental thermal and mechanical issues related to power electronics in harsh automotive environments; looking at issues surrounding the design and manufacture of main drive and peripheral converters, as well as existing and new semiconductor materials including silicon carbide and gallium nitride.


• The comprehensive development of a hybrid electric vehicle systems architecture

• A comprehensive study of communication protocols and diagnostic routines in hierarchical structures

• An investigation into drive cycles and vibration profiles

• An innovative computer simulation tool for analysing the electro-thermal behaviour of Insulated Gate Bipolar Transistors (IGBTs) and diodes

• A conceptual design for a new power electronics vehicle system

• A new conceptual design for an inverter

• A new conceptual design for a DC to DC convertor considering alternative topologies, their advantages and disadvantages, efficiencies and requirement specifications

• A new conceptual design for a battery charging system considering electrical and geographic requirements, power ranges, intelligent charging and security

• A new clean room facility for device manufacture


A new inverter has been developed to work in conjunction with the electric machine validation unit developed by the project. Zytek Automotive is planning to adopt the technology and manufacturing techniques in a new range of inverters that will meet demanding customer requirements. As a world-class supplier of electric drive systems it is critical for Zytek Automotive to demonstrate a full capability to their customers across the world.

Ricardo has successfully designed and tested a more efficient version of one of their current range of DC-DC converters. Ricardo will utilise the knowledge gained from the development of this new product within their consultancy services.

Tata Motors European Technical Centre (TMETC) has continued to develop the hybrid electric vehicle systems architecture further (including its development process) and has begun immediate application on new low carbon vehicle developments.

Lead Partner

WMG


Ricardo, Tata Motors European Technical Centre (TMETC), Zytek Automotive

08

High Voltage Electrical Distribution Systems (HVEDS)The new generation of electric and hybrid vehicles demand a lightweight, flexible and safe system for distributing high voltages around the vehicle. Our work in this area centred on enabling technologies to produce a generic, safe, scalable, lightweight and low cost HVEDS that is standards compliant.


• A comprehensive design guidebook covering the major aspects of high voltage distribution systems and related automotive standards

• An investigation into past and projected industry trends in this field

• A study into charging system interfaces and cables

• A proposal for optimising the system design architecture

• A computer simulation model to enable the virtual testing of new high voltage electrical system concepts

• A study considering manufacturing, assembly, safety, servicing and recycling aspects


Tata Motors European Technical Centre (TMETC) developed the concept for a design guidebook and coordinated input from project partners. The guidebook emphasises the combined research by demonstrating the relevance of the combined material to the HVEDS requirements. A comprehensive case study is included to give an example of applied methods and techniques and how to apply this to achieve a realistic electric vehicle design.

A new cable-sizing tool has been developed by Ricardo to allow initial high voltage cable cross-sectional areas to be estimated, based on system voltage and power ratings. Parameters were derived from thermal models and validated using experimental data. The application of this tool is part of the case study within the guidebook. This innovative free-standing tool will be used by Ricardo in conjunction with their cable database.

Lead Partner

Tata Motors European Technical Centre (TMETC)


Jaguar Land Rover, Ricardo, WMG, Zytek Automotive

09

Auxiliary Power Units The range of electric vehicles is often limited by the useable energy capacity of the onboard batteries. Range can be extended by carrying an onboard charging source known as an Auxiliary Power Unit (APU). Our focus was on optimising current APU technology and developing new ideas for the next generation of Range Extended Electric Vehicles (REEV).


• A roadmap of current and future auxiliary power unit technologies

• A technical requirements specification for an APU

• A packaging study integrating the APU into an LCVTP GTV vehicle, including studies to optimise the NVH characteristics

• An analytical study of the benefits of REEV compared to other architectures

• Testing and analysis to inform and validate future APU design

• Testing and analysis to optimise APU after treatment to achieve legislated emissions levels

• APU hardware to demonstrate a new APU utilising a state of the art volume production gasoline engine and a Ricardo designed bespoke generator in a REEV GTV vehicle


Working together, the project partners undertook the major task of designing, building, testing and validating a new auxiliary power unit which utilised a state of the art volume production gasoline engine. They also worked closely with the drive motors team to integrate a bespoke design APU generator.

Tata Motors European Technical Centre (TMETC) and Ricardo used simulation software to evaluate the potential efficiency benefit of using Atkinson & Miller cycle engines for APU applications; the TMETC analysis was validated by converting an existing Otto cycle engine to Atkinson cycle operation for objective measurements at MIRA. Computer simulation models were also used to investigate the benefit of a wide range of other base engine modifications for the specific APU duty cycle. The results will be used to inform the design of future APU engines.

Ricardo and MIRA worked together testing and developing the APU hardware and operating strategies, in upgraded testing facilities. Coventry University provided support on the emissions data analysis and studied the optimum requirements for after treatment in a range-extended electric vehicle application. Ricardo integrated the new APU into a current-production Jaguar Land Rover validation vehicle.

The knowledge gained will aid the specification and design of more efficient, compact, quieter and cost effective APUs for competitive low carbon range extended electric vehicles. The results from undertaking this challenging task are already being utilised in future advanced vehicle engineering programmes.

Lead partner

Ricardo


Coventry University, Jaguar Land Rover, MIRA, Tata Motors European Technical Centre (TMETC), WMG

10

Vehicle Supervisory Control The electrification of cars is driving the development of new complex control strategies, hardware and software. Our focus was a holistic approach to modelling, designing and testing control systems.


• A comprehensive study of safety protocols for vehicle control systems

• A diagnostic strategy for hybrid and electric vehicle (HEV/EV) control systems

• Technical specification, design and build of supervisory controller suitable for use in safety critical applications

• A suite of computer simulation models to appraise vehicle and sub-system controllers

• A proposal for a generic hybrid control architecture including control algorithms for optimising vehicle performance, energy management and driveability

• A basic implementation of the Vehicle Supervisory Controller (VSC) architecture was developed and deployed on Tata Vista EVX and Jaguar XJ demonstrator vehicles


Jaguar Land Rover has utilised the tools above to develop a Next Generation Control Architecture (NGCA) and control strategies for hybrid electric vehicles. The NGCA can be transferred into different vehicle platforms and derivatives through prototype vehicle builds to series production, resulting in major savings in both cost and time.

Ricardo has designed a new supervisory controller using a 32-bit processor with an integrated safety feature. Low level software and a high level design environment have also been developed to allow integration with the high level control algorithms developed in modelling environments. These products will be a valuable addition to Ricardo’s capabilities.

WMG led the collaborative development of a standardised HEV systems modelling framework based on WARPSTAR 2+ (WARwick Powertrain Simulation Tool for ARchitectures). Project partners developed a library of new powertrain and electric machine models in the DYMOLA environment. This will greatly reduce the time required to develop complex vehicle level models.

Tata Motors European Technical Centre (TMETC) has applied the new architecture to the Tata Vista EVX vehicle; initially for development, but with a view to a production unit. TMETC has also applied a generic control architecture to their current hybrid programmes.

WMG and MIRA have developed the concept of a Hybrid System Safety Monitor. Diagnostic strategies and algorithms were developed through Hardware-in-Loop (HiL) testing with simulation models and then applied and correlated on a running Range Extended Electric Vehicle (REEV). TMETC is looking to apply this learning to future production vehicle programmes.

Lead Partner

Jaguar Land Rover


Coventry University, Cranfield University, MIRA, Ricardo, Tata Motors European Technical Centre (TMETC), WMG

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Lightweight StructuresThe new architecture associated with hybrid and electric vehicles offers considerable opportunities for reducing overall vehicle weight and improving fuel economy, whilst maintaining desired levels of vehicle performance targets. With this in mind the project has researched, developed and proven innovative materials and process solutions for structural applications. These materials and process solutions will contribute to a significant reduction in the overall environmental impact of future vehicles.

Following an in-depth study into the current state of the art for automotive materials, two materials and process technologies were identified for further research that could offer lightweight solutions.

• A rapid stamp-forming process for thermoplastic composites that offers up to 50% weight save over conventional materials:

° Fully defined high volume production route, suitable for deployment in existing stamped metal supply chain

° Validated in the production of two demonstrator components (structural seat back and front longitudinal component)

° Benchmarked against conventional metallic material production routes in terms of cost, performance, environmental impact and volume production considerations

° Robust modelling capability proven, allowing accurate performance predictions by automotive engineers

° Effective and industrially-relevant joining approach formulated to allow the incorporation of structural elements manufactured from alternative materials into existing Body In White (BIW) structures

Lead Partner

WMG


Alpha Adhesives, Coventry University, GRM, IDC, Jaguar Land Rover, MIRA, Ricardo, SPMJ Technology Ltd, Tata Motors European Technical Centre (TMETC)

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• Hot-forming of Ultra High Strength (UHSS) boron steels:

° Implementation of the hot-forming process in conjunction with project partners

° Production of UHSS demonstrator components (front longitudinal section)

° Evaluation of resultant UHSS mechanical properties

Research was also conducted in the following areas:

• A study into, and identification of, lightweight vehicle glazing system opportunities

• Environmental impact assessment:

° Creation of a rapid, easy to use tool for calculating vehicle life-cycle CO2 performance

° A complete ‘top down’ life-cycle CO2 review of the LCVTP vehicle incorporating technologies identified and developed during the project

• A detailed predictive design study into the design opportunities afforded by future hybrid and electric lightweight vehicle architectures


Alpha Adhesives, working closely with Tata Motors European Technical Centre (TMETC) and WMG, has developed advanced adhesives specifically designed for applications within next generation vehicles including the effective structural joining of alternative and conventional materials.

TMETC and WMG have developed an innovative seat back structure using rapid-stamp formed thermoplastic composites that has been proven to relevant international standards. From the results of this study, engineers have now created a full seat specification that offers a weight saving in excess of 40% as compared to traditional steel-based structures.

TMETC and WMG have developed a structural element (longitudinal beam) that provides a 20% weight saving when compared to aluminium and around 50% saving when compared to steel. The new tooling was designed to work with both existing metal stamping equipment and within a new composite forming process.

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“The LCA studies have shown that the LCVTP low carbon technologies can significantly reduce the life cycle CO2 emissions of passenger cars”

Batteries

Lighter, flexible, and more energy efficient battery modules and packs validated using a suite of sophisticated software tools and state of the art testing equipment, together with a new Battery Management System (BMS).

Auxiliary Power Unit

A completely new APU designed, built and tested by the project partners, fully validated on a dynamometer and integrated into an existing vehicle package.

Dynamics and Control

New designs for vehicle control systems, with improved electronics hardware and fast-response software. Significant improvements in regenerative braking, power electronics, high-voltage cabling and energy storage and recovery systems.

Material Joining

A range of new advanced adhesives specifically designed for applications within next generation vehicles including the bonding of aluminium to composites, steel to composites, composites to composites and aluminium to steel.

Key Technology Achievements

The Life Cycle CO2 Assessment of LCVTP Technologies

The many technologies developed by the Low Carbon Vehicle Technology project are aimed at reducing the in-use carbon emissions of future vehicles. But tailpipe emissions alone do not necessarily tell the whole story, and so the project has also considered how these technologies compare on a life cycle basis.

Working with JLR, WMG and SPMJ Technology Ltd, Ricardo has applied Life Cycle Assessment (LCA) techniques to understand the potential life cycle CO2 footprint of a future vehicle using LCVTP technologies and components. This analysis has considered the carbon emissions from production of the vehicle, the production and use of fuel during the life of the vehicle, and from final disposal of the vehicle. For plug-in electric vehicles the CO2 produced from generation of the electric power has also been considered.

The life cycle CO2 study has shown that the LCVTP low carbon technologies can significantly reduce the life cycle CO2 emissions of future passenger cars. Furthermore, as the carbon intensity of the electricity grid reduces in the future as expected, the benefit of the LCVTP technologies will further increase.

The project team have also developed easy-to-use tools, suitable for non-expert users, to enable a life cycle approach to be adopted throughout the design and development process of future low carbon vehicles. These tools will allow the partner organisations to conduct rapid life cycle assessments, so that design engineers can carry out initial assessments before the release of components to vehicle programmes.

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Aerodynamic Improvements

New body and wheel features were developed and tested in a range of conditions, resulting in a significant reduction in overall vehicle drag.

Efficient Passenger Comfort and Information Systems

New efficient ways for heating and cooling the vehicle cabin were developed and tested, resulting in a saving of energy. New ways of presenting information to encourage energy efficient driving were developed and successfully trialled on a driving simulator.

Carbon Emissions Life Cycle Assessment

A suite of new tools for assessing the total carbon footprint of a vehicle over its lifetime, capable of providing valuable knowledge to vehicle designers, engineers, manufacturers, owners, operators, policy making bodies and recycling agencies.

Lightweighting

A highly innovative seat-frame design using rapid-stamp formed thermoplastic composites resulting in a weight saving of 40%. A new design for a longitudinal beam that provides a 20% weight-saving when compared to aluminium and 60% weight-saving when compared to steel. The designs have been validated using newly developed virtual and physical testing methods.

Energy Efficiency

Analytical tools and practical solutions have been developed to reduce energy losses through driveline systems, alongside empirical validation of waste energy recovery and conversion techniques that could be utilised to maximise onboard energy efficiency to increase electrical range and/or reduce tailpipe emissions in REEV applications.

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Aerodynamic PerformanceThe energy losses produced by aerodynamic drag are widely recognised as an area where improvement will lead to efficiency gains in vehicles at potentially modest cost. As such, it is an essential component of the overall drive towards the adoption of low carbon technology within the automotive industry. The project took an integrated approach to this problem, adapting automotive design processes and technologies to the design, manufacture and test of innovative vehicle body forms and devices.


• Comprehensive technology benchmarking study

• Conceptual designs for body devices to reduce vehicle drag

• Computer simulation model validated through wind-tunnel testing of concept vehicles fitted with aerodynamic features and devices

• Use of model scale and full scale tunnels for the development of aerodynamic concepts and to carry out correlation

• Validated results of fixed ground wind tunnel testing by testing at a moving ground facility

Lead Partner

Coventry University


Jaguar Land Rover, MIRA, Ricardo, Tata Motors European Technical Centre (TMETC)

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Open source Computational Fluid Dynamics (CFD) software was used for aerodynamic investigations, and many simulations were carried out, providing directions and correlation data for wind tunnel testing.

MIRA has further developed its capability in Large Volume Airflow Visualization (LVAV) techniques. The advantages of LVAV over current techniques such as Particle Image Velocimetry (PIV), is that it covers a large three-dimensional volume rather than a slice of the flow, whilst still offering accurate, transient, 3D position and velocity data capture. Rapid post-processing of the data provides engineers with a detailed insight into the flow structure; something which usually takes much longer when using traditional CFD methods.

Base pressures were a key area of research and development, and several concepts were tested, leading to significant reductions in drag. Drag reduction from wheel, and wheel arch modifications, was also investigated at model and full scale levels, as well as in fixed and moving ground tests.

Ricardo has performed a sensitivity analysis of aerodynamic drag over various drive cycles. This analysis has helped the investigation and evaluation of a range of state of the art passive and active devices and concepts used to improve aerodynamic performance. Ricardo used the vehicle fuel consumption and electric range model (called ‘VSIM’ and developed in Matlab Simulink) used in other areas of the project to quantify the electric energy consumption, regenerative braking and electric vehicle range over real world and legislative drive cycles (Artemis and NEDC).

The results are being considered by Jaguar Land Rover and Tata Motors European Technical Centre (TMETC) for incorporation into new vehicle wheel and wheel bay designs.

For Coventry University, the knowledge and experience gained through this workstream, in addition to its existing design, simulation and prototyping assets, has provided a step change in its engineering capabilities and expertise. It can now offer a comprehensive aerodynamics service from design critique to a managed test programme.

Leading Partner

Jaguar Land Rover


Coventry University, MIRA, Ricardo, Tata Motors European Technical Centre (TMETC), WMG

The cooling requirements for hybrid and electric vehicles present different challenges from those of conventionally powered vehicles. Batteries and circuitry can generate a large amount of heat which needs to be dissipated, and many components are susceptible to failure if the temperature of their immediate environment falls outside a relatively narrow band. Low carbon vehicle HVAC and cooling systems therefore need to be designed not only to meet the expectations of the user, but also to promote efficiency through reduced energy wastage.

Maintaining a comfortable temperature within a vehicle cabin without placing a heavy load on the battery is becoming a significant factor in hybrid electric vehicle design.


• Validated concepts for cooling major functional systems in low carbon vehicles including engines, power electronics, control units, machines and batteries

• Validated control algorithms for cooling and heating systems

• A new design proposal for an electric air-conditioning system

• Concepts to improve cabin heating and cooling efficiency in electric vehicles whilst maintaining thermal comfort for occupants, thus reducing energy wastage

High Efficiency Heating, Ventilation and Air-Conditioning (HVAC) and System Cooling

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MIRA used to gauge thermal comfort either by in-vehicle temperature measurement or by using proprietary temperature predicting software. However, human comfort is influenced by a number of factors including air flow, solar load, humidity, clothing and metabolism. The project team incorporated a human manikin, with a representative physiological model behind it, into their existing heat transfer analysis software. This is a huge step forward for thermal prediction as it enables MIRA to evaluate the impact of a range of factors on human comfort, rather than just focusing simply on temperature measurements.

Jaguar Land Rover is utilising the project results to accelerate research into new high efficiency electric air-conditioning systems and to establish investigation into heating technologies designed to compensate for the lack of waste heat from an internal combustion engine. This work will provide the foundations of enabling technologies allowing future development of vehicles that utilise high efficiency propulsion.

Coventry University’s COGENT team have been working with Jaguar Land Rover to expand its work on the management of human thermal environments. This has moved academic knowledge forward including proposals for better sensing techniques in-vehicle, allowing a more effective

measurement of thermal comfort. Jaguar Land Rover and COGENT’s work has also included investigation into using existing components to implement an algorithm designed to keep conditioned air in the cabin while minimising the build-up of CO2.

WMG and Tata Motors European Technical Centre (TMETC) have worked together to develop cooling control systems that can improve the efficiency of cooling systems used to control the temperature of various elements of electric and hybrid electric vehicles. The work done as part of this project has served to accelerate the development of electric vehicles while establishing a greater expertise in the West Midlands.

Ricardo has developed a thermo-hydraulic model of the cooling circuit and air conditioning of the EV and REEV and developed a model for the prediction of the impact on vehicle range by the loads placed on the vehicle’s power train due to powertrain and cabin cooling and heating. This puts Ricardo in an excellent position as a partner to OEMs developing low carbon vehicles.

Ricardo and MIRA have worked together to develop, assess and validate proposals for ways to control the heat lost and energy gained by the cabin of a vehicle. Both partners are now better placed to provide expert advice to vehicle OEMs.

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Reduction of Parasitic LossesMany conventional systems within vehicles offer renewed opportunities for reducing parasitic energy wastage, namely through driveline and transmission (friction reduction through fast warm up, bearing and bearing surface technologies and advanced lubricants), and chassis (reduced rolling resistance through low rolling resistance tyres, steering/suspension geometry, low drag brake callipers, electric power steering). However there is room for improvement in these areas.


• A fully correlated, integrated CAE model that can simulate parasitic losses at vehicle, subsystem and component level

• A sensitivity study approach to identify the major systems and components contributing to parasitic losses for both a convention internal combustion and electrically powered passenger car

• A comprehensive meta-study of research into parasitic loss reducing technologies

• Evaluation of a number of production feasible parasitic loss reducing technologies using the simulation model. The study demonstrated that the cumulative improvements to the gearbox, driveline, tyres and low voltage electrical system are comparable to those that could be realised through aerodynamic improvements alone

• Gearbox and low voltage electrical efficiency measurements to assist with simulation model validation


The project partners have jointly developed a new analytical tool for predicting fuel economy and electric vehicle range which can also identify the relative efficiency and loss contribution of individual components and systems. This enables advanced lower friction and electrical energy technologies to be evaluated using simulation tools instead of the more traditional and costly testing route. The energy flows and losses can be easily be mapped and the model adapted for a variety of vehicle and powertrain configurations.

Coventry University, along with Jaguar Land Rover and Ricardo, has conducted benchmarking of low voltage electrical loads on a suite of recent EV and hybrid vehicles against similar conventional vehicles. The University has supported detailed simulation of the efficiency sensitivity to the power demands of the low voltage electrical system. The work has led to a greater understanding of low voltage systems and their overall impact on vehicle efficiency, enhancing Coventry University’s capability to further investigate and develop technologies identified as a means to improve low carbon vehicles.

The parasitic loss technology database will assist the project partners to continue to improve vehicle efficiencies via the implementation of advanced low friction and energy loss components and systems, whilst respecting the economic and logistics constraints.

Lead Partner

Ricardo


Coventry University, Jaguar Land Rover, WMG

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Waste Energy Recovery and Alternative Energy StorageIf waste heat, kinetic or potential energy in vehicle powertrains can be accessed and suitably stored until needed, then large efficiency gains leading to a significant reduction in tailpipe CO2 emissions are possible.

Methods of energy recovery include exhaust heat extraction for warm up (cabin, engine, battery and electronic systems), the use of the organic Rankine cycle, thermoelectric generator using thermoelectric materials (Seebeck effect), electrical turbocompound, thermo-voltaic heat-pumps and chemical reactions. Intrinsically linked with this challenge is the identification and development of storage technologies to hold collected energy. Both recovery and storage technologies have challenges that must be overcome to facilitate mainstream application. If cost effective solutions can be established then such technology is likely to be a critical element in future low carbon vehicles.


• A technology survey indicating state of the art developments in energy recovery, waste heat recovery (from high grade and low grade heat) in the form of ‘Heat to Power’ or ‘Heat to Cool’ systems

• A suite of validated computer simulation models capable of analysing energy flows and assessing which amount of energy (thermal/mechanical/electric) can be recovered and/or stored over different real world and legislative drive cycles

• System and sub-system FMEAs indicating good design practices

• Data from practical tests on selected systems

• Material characteristic data from Thermolectric Generator and Phase Change Material test rigs

• Simulation study into ‘Heat to Cool’ (absorption, adsorption) for Range Extended Electric Vehicle (REEV) applications

• Assessment of magneto caloric heating and cooling for EV and REEV applications - linked with high efficiency HVAC systems


The project partners have jointly developed a system models for determining energy recovery opportunities from electric vehicles and REEV. Where applicable the system models have been integrated into the project vehicle model to assess the fuel consumption/energy benefit of the system.

The project partners have generated material parameter data from the hardware test rigs to enhance the accuracy of the modelled systems and understanding of material behaviour.

Lead Partner

Ricardo


Coventry University, Jaguar Land Rover, WMG

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Vehicle Dynamics and Traction Control Here we have focused on combining regenerative and friction braking technology to ensure maximum energy recovery whilst ensuring safety (vehicle stability and traction).


• A comprehensive state of the art technology analysis which included a hybrid/electric vehicle benchmarking programme

• Analysis of current braking legislation requirements and the implications upon design for hybrid/electric vehicles

• A suite of hydraulic braking models able to simulate a range of modulator and braking system architectures and indicate how to control the creation of hydraulic pressure via an electronic demand

• A vehicle handling simulation toolset which models the vehicle and regenerative braking dynamics for various hybrid/electric vehicle and brake system architectures

• Research into brake blending and vehicle stability control algorithms utilising the CAE toolsets that were developed in the project

• A working prototype rheostatic braking system that is able to dissipate large amounts of braking power independent of the foundation braking and high voltage battery systems


The partners have jointly developed a new brake resizing investigation tool which enables the designer to quickly resize the friction brake package and combine with a regenerative brake system on an existing vehicle platform. Tata Motors European Technical Centre (TMETC) utilised this tool to evaluate brake energy capture potential over standard drive cycles.

MIRA can now offer consultancy related to legislative requirements for regenerative braking systems, and with TMETC, have attained knowledge of state of the art bespoke benchmarking procedures.

Coventry University has developed a sophisticated brake torque apportionment controller, responsible for governing the regenerative and friction torques sources.

Cranfield University has developed a brake vacuum booster testing rig to help validate their detailed modelling and simulation activities of the friction brake system.

WMG has developed a reduced 1st order hydraulic brakes model library. This framework has been used extensively in the model-based development of complex regenerative brake control systems and their evaluation in terms of overall energy recovery and impact on vehicle dynamics.

All models are real-time capable and have been successfully implemented on an IPG Automotive XPack4 Hardware-in-Loop (HiL) platform, to perform real-time validation and verification of control systems, and to study the impact of signal propagation delays over Controller Area Network (CAN) and FlexRay communication networks.

Ricardo has investigated the application of the IPG carmaker ABS algorithm with respect to its application as a basis for investigating the interaction between regenerative braking and stability control systems.

Lead Partner

Jaguar Land Rover


Coventry University, Cranfield University, MIRA, Ricardo, Tata Motors European Technical Centre (TMETC) and WMG

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Human-Machine Interface EngineeringTo aid customer acceptance, and improve the user experience of future low carbon vehicles, it is vital to consider the Human-Machine Interfaces (HMI) from a user-centred perspective. Specifically, this means understanding the interaction between the driver/passenger and the vehicle, and designing the user interface to maximise usability, satisfaction and enjoyment.

Advances in technology are creating additional issues such as novel starting/stopping procedures, or communicating the effect that driving style has on the potential mileage range. Project teams focused on developing new techniques for trialling and evaluating new concepts and HMI issues within hybrid electric and pure electric vehicles.


• A comprehensive review of methods and technologies used to aid driver interaction

• A quantitative and qualitative analysis of driver feedback relating to HMI issues

• The development of new methodologies for capturing voice-of-the customer feedback from low carbon vehicle drivers

• A range of conceptual HMI solutions trialled on a driving simulator


Jaguar Land Rover has produced a set of standards covering HMI aspects relating to hybrid electric vehicles to ensure consistency across platforms and brands, utilising the results relating to hybrid electric vehicle issues including: charging port design and location, touchscreen characteristics, instrument cluster content, warning messages and the breadth and depth of information presented in different vehicle power modes.

Tata Motors European Technical Centre (TMETC) has developed driver information methods for electric vehicles to address the challenge of range anxiety. The results of work into remote feedback and range information have been used to develop electric vehicle driver information management systems. The expertise gained here is also being used in the development of future cross-platform infotainment systems.

Lead Partner

WMG


Coventry University, Jaguar Land Rover, Tata Motors European Technical Centre (TMETC)

Lead Partner

Ricardo


Jaguar Land Rover

Vehicle Integration and Validator PlatformsThere are a number of major challenges in designing, testing and manufacturing high volume passenger vehicles incorporating emerging technologies.

Three vehicle teams, with expertise from all partners, undertook the challenge, both virtually and physically, to prove out the technologies and processes developed across the project.


• A set of vehicle, system and technology targets for a large saloon concept vehicle

• A set of vehicle, system and technology targets for a sports utility concept vehicle

• A set of vehicle, system and technology targets for a small size but high occupancy hybrid electric concept vehicle

• A suite of new design, information sharing and target setting processes that integrate the complexities of hybrid vehicle development

• Three virtual validation platforms

• A physical sports-utility validation vehicle in two variants; all-electric propulsion and hybrid-electric propulsion

• A safety integration strategy incorporating a whole vehicle FMEA

• A new systems engineering methodology

• A set of new vehicle architecture concepts

• A real world pure electric vehicle drive cycle has been developed from logged Vista EV data

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For Tata Motors European Technical Centre (TMETC) the objective of this work package was to develop a novel concept based on a vehicle to match the optimum segment identified for an EV and a Range Extended Electric Vehicle (REEV) that has, amongst its objectives, leadership in both aerodynamic performance and occupant package. This concept was the source of targets to the technology workstreams to investigate the maturity of the required technologies and their ability to meet the requirements. Concept development and validation were undertaken primarily in a virtual environment.

Vehicle usage data from Vista EVs participating in the CABLED (Coventry And Birmingham Low Emission Demonstration) Programme was analysed to develop a real world electric vehicle drive cycle used to support vehicle performance target setting. This learning is being implemented on future low carbon vehicle and technology programmes within TMETC.

Ricardo has built and developed two variants of a technology demonstration platform, developed through three key stages of work within the project. Initially, the technology demonstration platform provided technical and physical targets which have been adopted by some of the project activities to provide a focal point for technology development. As a result, the ultimate

goal to create a REEV architecture incorporating an advanced auxiliary power unit (a gasoline engine integrated with a generator) developed within the project has been achieved. The inherent flexibility in the mechanical and electrical architecture will provide the basis for ongoing research and development such as enhanced control strategies for HVAC and other systems to further optimise comfort and energy efficiency.

Following completion of its work within the project, Ricardo will continue to evolve the electric vehicle technology demonstration platform through further technological stages to realise the breadth and depth of research and development that Ricardo is investing in within this field.

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Key ContactsCoventry University

Mike Dickison Commercial Director Faculty of Engineering & Computing [email protected] www.coventry.ac.uk

Jaguar Land Rover

Mike Richardson Manager Advanced Hybrids [email protected] www.jaguarlandrover.com

MIRA

Lisa Bingley Project Manager [email protected] www.mira.co.uk

Ricardo plc

Corin Wren Programme Manager [email protected] www.ricardo.com

Tata Motors European Technical Centre

Johnathan Breddy Project Manager [email protected] www.tatamotors.com

WMG

Alan Curtis Chief Executive Officer, High Value Manufacturing Catapult [email protected] www.wmg.warwick.ac.uk

Zytek Automotive

Aiden Gregory Technical Director [email protected] www.zytekautomotive.co.uk

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mailto:[email protected]

www.coventry.ac.uk


www.jaguarlandrover.com


www.mira.co.uk


www.ricardo.com


www.tatamotors.com


www.wmg.warwick.ac.uk


www.zytekautomotive.co.uk

Printed on 100% recycled paper Photography by Michelle Tennison: www.tennisons.co.uk

Design by DC Group: www.dcgroup.uk.net

The information contained in this brochure was correct at the time of going to print. For updates and latest information, please check our website www.warwick.ac.uk/go/wmglowcarbon

www.tennisons.co.uk

www.dcgroup.uk.net

www.warwick.ac.uk/go/wmglowcarbon

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