Periodic Reporting for period 1 - REFLECTIVE (RECONFIGURABLE LIGHT ELECTRIC VEHICLE)
Reporting period: 2021-02-01 to 2022-07-31
The simultaneous increase in the transport related emissions and urbanisation of societies is generating an unparalleled demand for less polluting and more efficient ways of moving. For the European Union, the targets have been set clearly in the European Green Deal: 1) a drastic 90% reduction in the transport emission is needed by 2050 and 2) new sustainable mobility services with supporting infrastructure are the key to reduce the pollution and congestion.
Reconfigurable light electric vehicle “REFLECTIVE” aims at introducing a L7 category light vehicle concept that could be safely, conveniently and efficiently operated in various urban environments and missions. On a higher level our objectives are to mitigate the negative effects of vehicles on the global environment through electrification, rightsizing and intensification of the usage of the vehicles. Simultaneously, our concept could make the moving in cities and urban areas more convenient.
Our first technical objective is to propose a powertrain configuration that could be easily adaptable from L7 to M1 category vehicles. The powertrain will be rightsized for urban missions, both in terms of installed power and energy capacity. Through further optimisation of the energy management, in total 10% decrease in the energy consumption for typical urban profiles is aimed at. Second technical objective is to increase the passive safety of the L7 category vehicles remarkably without losing the adaptability of the vehicle to different urban use cases, from the transport of people to the transport of goods. Third, we aim at improving the overall usability and attractiveness of the concept via charging flexibility and limited automated features for instance for parking or charging. The fourth technical objective is to test the REFLECTIVE vehicle both in laboratory environment and traffic for validating its efficiency, usability, and safety. Last, we aim at communicating and disseminating the project results as widely as possible for different audiences to gain feedback but importantly to promote the outcomes of our project and their market uptake.
Reconfigurable light electric vehicle “REFLECTIVE” aims at introducing a L7 category light vehicle concept that could be safely, conveniently and efficiently operated in various urban environments and missions. On a higher level our objectives are to mitigate the negative effects of vehicles on the global environment through electrification, rightsizing and intensification of the usage of the vehicles. Simultaneously, our concept could make the moving in cities and urban areas more convenient.
Our first technical objective is to propose a powertrain configuration that could be easily adaptable from L7 to M1 category vehicles. The powertrain will be rightsized for urban missions, both in terms of installed power and energy capacity. Through further optimisation of the energy management, in total 10% decrease in the energy consumption for typical urban profiles is aimed at. Second technical objective is to increase the passive safety of the L7 category vehicles remarkably without losing the adaptability of the vehicle to different urban use cases, from the transport of people to the transport of goods. Third, we aim at improving the overall usability and attractiveness of the concept via charging flexibility and limited automated features for instance for parking or charging. The fourth technical objective is to test the REFLECTIVE vehicle both in laboratory environment and traffic for validating its efficiency, usability, and safety. Last, we aim at communicating and disseminating the project results as widely as possible for different audiences to gain feedback but importantly to promote the outcomes of our project and their market uptake.
During the first period of REFLECTIVE, the main subsystems of the vehicle have been defined, the chassis, powertrain, transmission, charging, thermal management, and automated driving system (ADS) layouts. The main structures of the vehicle have been developed and optimised for increased passive safety through extensive simulation activities. Appropriate restraint systems have been chosen. The vehicle styling and looks are almost ready and finishing touches on the exteriors and interiors are being made. For the most part, the design of the full assembly of the REFLECTIVE L7 category vehicle has been carried out. However, some changes are still possible due to the ongoing further safety assessments, wiring harness and tube connections and procurement of smaller components.
Accommodating the different advanced features has been an interesting and challenging task involving compromising between the subsystem specifications and designing certain features, namely, e.g. ADS, that could be provided to end users of the REFLECTIVE L7 category vehicle as an enhanced “safety kit” value-adding add-on rather than as a permanent installation. Due these measures, we are able to serve larger number of use cases effectively, utilising the most advanced or costly features only when they are absolutely needed. This allows us to achieve an optimal balance between technical performance and cost-efficiency, to increase the overall commercial attractiveness of the new vehicle. In the big picture, the project has progressed as planned, and the build-up of a second mock-up version of the vehicle can begin in October 2022.
Accommodating the different advanced features has been an interesting and challenging task involving compromising between the subsystem specifications and designing certain features, namely, e.g. ADS, that could be provided to end users of the REFLECTIVE L7 category vehicle as an enhanced “safety kit” value-adding add-on rather than as a permanent installation. Due these measures, we are able to serve larger number of use cases effectively, utilising the most advanced or costly features only when they are absolutely needed. This allows us to achieve an optimal balance between technical performance and cost-efficiency, to increase the overall commercial attractiveness of the new vehicle. In the big picture, the project has progressed as planned, and the build-up of a second mock-up version of the vehicle can begin in October 2022.
During the first period of REFLECTIVE, we have made the following advancements beyond the state-of-the-art
• Designing of an efficient and scalable traction induction motor. The motor is free from critical raw materials resulting in lower costs. The motor and its control unit are scalable from L7 category to M1 category vehicles. The liquid cooling solution of the motor allows different mounting positions in the vehicle increasing its flexibility. The motor prototypes are in production for the laboratory testing and later installation in REFLECTIVE vehicle.
• REFLECTIVE vehicle will contain both conductive and wireless charging possibility. All the needed components have been purchased and their integration into the vehicle designed.
• Due to the extensive optimisation campaign, the structures and subsystems have been optimised for increased passive safety. So far the present L7 category vehicles have performed poorly in the Euro NCAP tests and REFLECTIVE aims at making a significant contribution in this respect.
• The interior design of REFLECTIVE will be adaptable to different urban use cases, with foldable seats on the back and add-on ADS systems.
• For the design and other development and utilisation purposes, we have in the beginning of the project created realistic driving and duty cycles for the light electric vehicles. In this work, the VTT Smart eFleet tool have been used and developed further. The outcomes are the driving cycles for Helsinki Capital Area, Finland and Regensburg, Germany.
• The thermal management has been designed energy savings and user comfort in mind. First, the battery can be heated with the hot air from the cabin during driving and during charging. Second, the cold air coming from the HVAC unit is sent to the battery in case of cooling needs. Again, this can be applied during charging as well. Further, during driving scenario, part of the heat from the cooling circuit at powertrain outlet, can be used for heating the cabin in winter scenario. By this way, it is possible to reduce the power absorption of the PTC, commonly used to heat up the cabin in EV HVAC systems. The possibility of recovering part of the heat from powertrain cooling circuit outlet, will be optimised together with the feature of bypassing the main radiator. By means of such a strategy, the main cooling circuit (powertrain) will be maintained at the optimal temperature for components safety, allowing not to “waste” energy at the radiator, but reusing it for cabin heating, with the contemporary reduction of the PTC power absorption.
• Designing of an efficient and scalable traction induction motor. The motor is free from critical raw materials resulting in lower costs. The motor and its control unit are scalable from L7 category to M1 category vehicles. The liquid cooling solution of the motor allows different mounting positions in the vehicle increasing its flexibility. The motor prototypes are in production for the laboratory testing and later installation in REFLECTIVE vehicle.
• REFLECTIVE vehicle will contain both conductive and wireless charging possibility. All the needed components have been purchased and their integration into the vehicle designed.
• Due to the extensive optimisation campaign, the structures and subsystems have been optimised for increased passive safety. So far the present L7 category vehicles have performed poorly in the Euro NCAP tests and REFLECTIVE aims at making a significant contribution in this respect.
• The interior design of REFLECTIVE will be adaptable to different urban use cases, with foldable seats on the back and add-on ADS systems.
• For the design and other development and utilisation purposes, we have in the beginning of the project created realistic driving and duty cycles for the light electric vehicles. In this work, the VTT Smart eFleet tool have been used and developed further. The outcomes are the driving cycles for Helsinki Capital Area, Finland and Regensburg, Germany.
• The thermal management has been designed energy savings and user comfort in mind. First, the battery can be heated with the hot air from the cabin during driving and during charging. Second, the cold air coming from the HVAC unit is sent to the battery in case of cooling needs. Again, this can be applied during charging as well. Further, during driving scenario, part of the heat from the cooling circuit at powertrain outlet, can be used for heating the cabin in winter scenario. By this way, it is possible to reduce the power absorption of the PTC, commonly used to heat up the cabin in EV HVAC systems. The possibility of recovering part of the heat from powertrain cooling circuit outlet, will be optimised together with the feature of bypassing the main radiator. By means of such a strategy, the main cooling circuit (powertrain) will be maintained at the optimal temperature for components safety, allowing not to “waste” energy at the radiator, but reusing it for cabin heating, with the contemporary reduction of the PTC power absorption.