Community Research and Development Information Service - CORDIS

H2020

ECOCHAMPS Report Summary

Project ID: 653468
Funded under: H2020-EU.3.4.

Periodic Reporting for period 1 - ECOCHAMPS (European COmpetitiveness in Commercial Hybrid and AutoMotive PowertrainS)

Reporting period: 2015-05-01 to 2016-10-31

Summary of the context and overall objectives of the project

Developing technologies for hybrid electric passenger and commercial vehicles that provide improved performance and comfort, lead to less CO2 emissions and will make hybrid vehicles more affordable. To increase both consumer and operator interest in hybrid vehicles, the project will extend their functionality and improve fuel economy whilst minimising their cost premium. The targets of ECOCHAMPS are: Improve fuel efficiency by up to 20%, Reduce powertrain weight and volume by up to 20% and Reduce hybrid vehicles costs, targeting a 10% maximum cost premium.

Standardisation of components will bring vehicle cost down. For commercial hybrid vehicles no such standards yet exist. The project will propose a Modular system and Standardisation Framework. It is the first time, that standards are to be recommended for hybrid electric powertrain components for commercial vehicles. A second way to reduce cost is modularisation which enables the use of the same hybrid electric components over different vehicle types ranging from light duty to heavy duty vehicles. The project consortium, consisting of 6 vehicle manufacturers, suppliers and research organisations, will deliver 5 demonstrator hybrid vehicles in total to prove and assess the success of the innovations. Another way to increase market uptake is to offer more vehicle functionality through the use of the hybrid technologies.

Work performed from the beginning of the project to the end of the period covered by the report and main results achieved so far

Target Setting, Tracking and Evaluation
The vehicle developments are based on the requirements defined the project. The aim is to improve and show the competitiveness of hybrid systems for LD and HD applications. To ensure these vehicles deliver what is required, a tracking task has been established, which provides an independent supervision over the ongoing development. The tracking is carried out by ‘Golden Engineers’ for LD and for HD.

Component Standardization, Modularization and Development
Hybrid electric components with improved functionality, performance and functional safety will be developed and implemented in highly efficient and cost optimized powertrains for LD and HD vehicles. The component development of LD vehicles will be done in conformity with existing standards for hybrid passenger cars. For HD vehicles no such standards exist. In order to achieve the objectives for HD vehicles, a pre-standard framework, the Modular System and Standardization Framework, for drivetrain components and electrically driven auxiliaries is developed. To work out standardization proposals, requirements for each component and on cross component level, have been identified and discussed, resulting in agreements on: system voltage levels, electrical and mechanical interfaces as well as communications interfaces, lifetime expectations and performance classes etc.
Light Duty: P-HEV e-AWD B class passenger car
The class B vehicle developments are based on a Fiat 500X. Designed as a plug-in hybrid with an electric range of 25 km. The vehicle features a parallel hybrid powertrain that is a combination of the structure variants P1f and P4. One electric motor is connected to the crankshaft of a small combustion engine, which propels the front axle (P1f), via an innovative belt drive (FEAD – Front End Auxiliary Drive). Additionally, a detachable electric motor propels the rear axle via a fixed transmission (P4). Component and System Design & Optimisation and defined control functions and strategies, followed by Component Integration, the plug-in hybrid powertrain subsystem bench validation are finished.
48V Hybrid C class passenger car
The class C demonstrator is a 48-V hybrid based on a Renault Megane. The aim is to demonstrate fuel economy figures comparable to those of a vehicle with a high voltage system, whilst halving powertrain costs by employing 48-V components. To increase powertrain efficiency, the downsized, turbocharged and friction optimised combustion engine is combined with an electric propulsion system. An intelligent energy management ensures that the gear selection is independently optimised for both combustion engine and electric motor. Powertrain specification, simulation and design at 15kW and 15kW system build, bench test and reporting, and Prototype vehicle build, functional test are finished and reporting.
Medium Duty Application
For the medium duty commercial demonstrator, Iveco equips a Daily delivery cab with a parallel hybrid powertrain. The battery will enable pure electric driving within a range of 20 km: A gearbox connects the high-speed electric motor to the cardan shaft leading to the rear axle. Additionally, the electric motor can be separated from the powertrain by a clutch. This allows the driver to manually switch the operating mode between pure electric, hybrid electric and combustion engine only. A flexible charging system offers the possibility to charge the high voltage battery with 400 V DC or conventional 230 V AC. The battery system itself is designed to be modular. Vehicle and systems specification are ready. And Hybrid Plug-in Vehicle design and components integration is done.

City Bus application
A serial hybrid bus from MAN will have a powertrain based on a newly developed electric propulsion concept. The main system components and the basic structure of the bus such as the chassis, will be modularised. The aim is to develop a basic electric bus which can be easily adapted based on customer and application requirements.
The pure electric basic powertrain can be extended with various energy supplies. A modular energy management will be developed. To achieve cost reduction, the evaluation of passenger car electric components application in hybrid busses. The demonstrator vehicle consists of powertrain components and battery systems that have originally been developed for passenger car applications. Final concepts and requirements are defined and demonstrator build up started.
Heavy Duty
The heavy duty unit from DAF, will be fitted with a parallel hybrid electric powertrain. An holistic and modular approach is pursued to efficiently combine the use of an electric Waste-Heat-Recovery (eWHR) system with a hybrid electric powertrain. Components from the high volume passenger car segment are to be used in the hybrid truck to achieve the set price targets. This results in the voltage level of 400 V for the electrical architecture. First route simulation results are available for hybridization comparison. Hybrid/eWHR concept designed and EE architecture defined. And Component integration for prototype truck done

Progress beyond the state of the art and expected potential impact (including the socio-economic impact and the wider societal implications of the project so far)

Achieving the innovations at affordable cost will strengthen the technological leadership in hybrid technology powertrain and system optimization, and increase the competitiveness of EU vehicle manufacturers. The technology will have a strong impact on the reduction of CO2 for road transport and improvements in air quality.
A modular framework (D2.1) that recommends standards for electric hybrid commercial vehicle drivetrain components and auxiliaries enabling standardization, interchangeability, scalability, economy of scale and cost efficiencies. A set of electric components for hybrid powertrains at TRL6/7, specifically for commercial vehicles, conform with the modular framework: Battery, EMG, Inverter EMG, DC/DC, Power steering and Air compressor.
Five advanced electric hybrid powertrains at TRL7, will be demonstrated. And will comply or outperform the relevant emissions targets under appropriate driving conditions

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