User-centred Optimal Design of Electric Vehicle with Smart E-Corners

Project Information

SmartCorners

Grant agreement ID: 101138110

DOI

10.3030/101138110

EC signature date 7 December 2023

Start date 1 January 2024

End date 31 December 2026

Funded under

• Climate, Energy and Mobility

Total cost

€ 6 317 719,99

EU contribution

€ 4 575 719,99

Coordinated by

AVL DITEST GMBH
Austria

Periodic Reporting for period 1 - SmartCorners (User-centred Optimal Design of Electric Vehicle with Smart E-Corners)

Reporting period: 2024-01-01 to 2025-06-30

Summary of the context and overall objectives of the project

In-wheel motors (IWMs) have become a mature technology that is well-suited for new user-centric electric vehicles (EVs). IWMs can be integrated in multi-functional and controllable modules consisting of the electric powertrain, friction brake and suspension/steering actuation. By combining several vehicle functionalities in a compact solution, the modules offer substantial opportunities to enhance the design and the operation of EVs. This is the starting point of the SmartCorners project.

Using machine learning and AI, an adaptive multilayer control strategy will be implemented with historical and current data from the vehicle, its environment, and users, including relevant EV fleets. This approach will pave the way toward software-defined vehicles, enabling rightsizing, holistic optimisation, innovative fault mitigation and actuator allocation strategies as well as more efficient, adaptive, predictive, and personalised system operation.

SmartCorners is organized around the following objectives
- (O1): Accelerated design and testing methodologies of adaptable, efficient, right-sized, flexible and user-centric smart corner systems (SCS) based on in-wheel powertrains
- (O2): New series of scalable and flexible SCS for next-generation EVs
- (O3): Predictive, user-centric, AI- and model-based control solutions for SCS equipped EVs
- (O4): Holistic thermal and passenger comfort management

SmartCorners is targeting the following impact
- Societal impact: Greenhouse gas and emissions reduction in road transport through transition toward e-mobility; increased electric vehicle (EV) acceptance with overall positive environmental effect.
- Economic impact: overall cost reduction of EVs (by 5...10% depending on the vehicle segment as compared to benchmarked EVs).
- Technological impact: new design of smart corner systems as components of promising EV architectures; new methods of DT-based validation of EV technologies (with >30 % reduction of the development time).
- Scientific impact: new concepts for user-centric EVs, their novel multi-physics development as well as the relevant manufacturing decision-support framework.

In conclusion, SmartCorners will provide a significant competitive advantage for the European industry thanks to the multi-disciplinary team and participative approach.

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

The following activities have been performed during the first reporting period:

Work Package 1 - Specification, conceptualisation and requirements
- Definition of the layout of the smart corner and the targeted vehicle control applications covered by SmartCorners;
- Definition of the requirements of the SmartCorners components and systems;
- Implementation of a simulation toolchain for the model-based design of the SmartCorners components and a toolchain for user-centric AI based controller design;

Work Package 2 - Powertrain and chassis layout of EV with SmartCorners topology
- Definition of the most appropriate SmartCorners suspension layout to properly accommodate IWMs;
- Study of the vehicle model layout enabling to enhance the SmartCorners architecture;
- Development of efficient and effective suspension actuators to properly control the ride dynamics;
- Development of adequate x by wire actuators to control the vehicle handling.

Work Package 3 - AI supported thermal and cabin comfort control
- Definition of a thermal system layout of the smart corner for the targeted vehicle and specify the components that are used for the thermal management;
- Development of an energy optimal control strategy for the defined thermal system of the power train;
- Combining this strategy with a user-centric cabin comfort control that ensures both ideal comfort and energy consumption;

Work Package 4 - Global design and control
- Seamless integration of powertrain and chassis controllers through a comprehensive software platform, ensuring efficient coordination and management of the EV's various systems, while enabling a 15% reduction in development time compared to traditional approaches;
- Development of a multi-level digital twin model of the EV with SmartCorners topology on component and system levels, achieving at least a 90% correlation between simulation results and real-world performance, allowing for effective optimisation of hardware components and software control algorithms;

Work Package 5 - Optimal, safe and secure operation on vehicle level
- Development of predictive control strategies to enhance dynamic performance of EV equipped with SmartCorners;
- User centric control solutions to adjust vehicle mission by utilising offboard data gathered by fleets of vehicles;

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)

SmartCorners are organized around the following "assets" and further refined in the following expected project results
Asset 1 “Wheel Corner Design”
- PR-01 Wheel Corner with IWM and integrated chassis actuators.
- PR-02 Novel integrated powertrain and chassis controller.
- PR-03 SW with adaptable RT AI module for wheel positioning control.

Asset 2 “User-centred Thermal and Cabin Comfort Management”
- PR-04 AI preconditioning of the thermal system control.
- PR-05 Adaptive use of recirculation flap.
- PR-06 AI adaption of the comfort settings to user preferences.

Asset 3 “Global EV Motion Control”
- PR-07 Slip control with dynamic tuning and vehicle speed estimator.
- PR-08 Pitch, roll and yaw control as a part of a simultaneous 6 DoF control.
- PR-09 Secondary mode damping control as a part of simultaneous 6DoF control.

Asset 4 “Smart EV Optimal Operation Management”
- PR-10 Virtual sensors, including road grip, wheel acceleration and suspension travel.
- PR-11 AI path planning.

Asset 5 “DT Methodology of User-centred EV design”
- PR-12 Digital twinning of EV with independent corners.
- PR-13 Digital Twin for AI training.

While writing this report (RP1), the project results are under development; the targeted objectives have been preliminary validated (simulation, lab) but further integration and evaluation in more realistic environment is still pending (focus of the 2nd reporting period). Parallel to this, consolidation of the target groups getting benefits from SmartCorners have been performed, and a dedicated engagement strategy has been designed. The main highlights for the engagement strategy are (a) end-user survey regarding the needs for human-centric e-mobility; (b) development of value proposition canvas and business model canvas for each of the project results, and participation to Horizon Results Booster in the first project year; (c) identification of "technology ambassadors" able to support the replication of the technology for different vehicle platforms / geographical markets; (d) continuous alignment with the R&D&I ecosystem (including policy makers) through participation to relevant conferences and expert groups (e.g. TRA, RTR, E-VOLVE cluster).

SmartCorners Project Overview

SmartCorners Partner Map

SmartCorners project Logo