Periodic Reporting for period 1 - MINDED (Thermal and energy Management for INcreased Driving range of an Electric minibus including improved user-centric Design and thermal comfort)
Periodo di rendicontazione: 2024-01-01 al 2025-06-30
Battery-electric minibuses are vital for sustainable urban transport, but their adoption is limited by short driving range – especially in cold climates where heating demands can consume up to a third of total energy. This reduces performance, comfort, and viability for public mobility services.
MINDED addresses this by aiming to boost the real-world range of an electric IVECO eDaily minibus by at least 20% at 0 °C, while improving thermal comfort, simplifying system design, and cutting costs. The project integrates ten technology bricks across three AREAS:
(I) Efficient heating and cooling (e.g. infrared panels, heat pump HVAC with oil-free e-compressor),
(II) Predictive, digital twin-based control using real-time data and AI, and
(III) Full system integration and TRL 6 – 7 demonstration.
A user-centric HMI reflects the project’s social science focus, collecting comfort feedback from drivers and passengers to refine thermal control.
Expected impacts include a ≥20% range increase, ≥5% vehicle cost reduction, and ≥30% cut in development time. These outcomes align with 2ZERO Partnership goals by supporting more efficient, affordable, and user-friendly electric mobility – key to advancing zero-emission transport.
MINDED addresses this by aiming to boost the real-world range of an electric IVECO eDaily minibus by at least 20% at 0 °C, while improving thermal comfort, simplifying system design, and cutting costs. The project integrates ten technology bricks across three AREAS:
(I) Efficient heating and cooling (e.g. infrared panels, heat pump HVAC with oil-free e-compressor),
(II) Predictive, digital twin-based control using real-time data and AI, and
(III) Full system integration and TRL 6 – 7 demonstration.
A user-centric HMI reflects the project’s social science focus, collecting comfort feedback from drivers and passengers to refine thermal control.
Expected impacts include a ≥20% range increase, ≥5% vehicle cost reduction, and ≥30% cut in development time. These outcomes align with 2ZERO Partnership goals by supporting more efficient, affordable, and user-friendly electric mobility – key to advancing zero-emission transport.
#Obj. 1 – IVECO Minibus Demonstrator
The IVECO minibus demonstrator is the central validation platform of the project. Two tests on a climate-controlled chassis dynamometer have been completed. Key technologies such as infrared heating and thermal insulation were integrated, and a validated digital twin of major systems (cabin, HVAC, battery, powertrain) was developed. This enables real-world system-level validation.
#Obj. 2 – Infrared Heating Panels Including Thermal Insulation
Infrared heating panels were installed on the floor and backrests of all 22 passenger seats. Tested in the second campaign with a basic control strategy, they support fast, energy-efficient heating. Cabin and heating system insulation were improved after analysis in the first test. These enhancements led to notable energy savings.
#Obj. 3 – User-Centric Designed HMI
An intuitive HMI was developed for both driver and passengers, running on touch displays. It enables comfort feedback and control of thermal systems. The driver version also offers full HVAC control, including air temperature settings. The design supports energy-efficient, user-responsive climate management.
#Obj. 4 – Optimised HVAC System
A heat pump-capable HVAC system with retained cooling and waste heat recovery was developed. A semi-indirect layout was chosen for optimal efficiency. It uses a direct evaporator and indirect condenser connected to a coolant loop. This enables efficient heating even in very cold conditions.
#Obj. 5 – Optimised Thermal and Energy Management
A predictive control strategy was implemented using a validated digital twin. Nonlinear model predictive control manages HVAC and IR heating while maintaining comfort via the PMV index. Driving behaviour prediction via ADAS and machine learning further enhances efficiency. Battery heating was also optimised to reduce thermal energy use.
#Obj. 6 – Driving Behaviour Prediction
Machine learning models were trained on ADAS datasets to predict short-term velocity profiles. A self-supervised module detects behavioural deviations in real time. Long-term forecasts use map and route data for aggregated driving metrics. These predictions support better thermal and energy planning.
#Obj. 7 – Real-World Range Increase
The project aims for a ≥20% range increase at 0 °C through combined innovations. Initial test campaigns show promising gains from IR heating and insulation. Further improvements are expected with NMPC and battery pre-conditioning in simulation. The final simulative validation will confirm target achievement under real-world conditions.
#Obj. 8 – Cost Reduction at Vehicle Level
Cost savings (>5%) are driven by use of an oil-free e-compressor and modular ECU architecture. These reduce system complexity, part count, and integration costs. Enhanced efficiency may allow for battery downsizing. Together, these contribute to lower total vehicle cost.
#Obj. 9 – Reduction of Development Time
A 30% reduction in development time is targeted using digital twins, model-based workflows, and AI. A calibrated 1D twin enables simulation and real-time validation. Machine learning accelerates controller design, including PMV estimation. MiL and HiL testing front-load development and reduce physical iteration.
The IVECO minibus demonstrator is the central validation platform of the project. Two tests on a climate-controlled chassis dynamometer have been completed. Key technologies such as infrared heating and thermal insulation were integrated, and a validated digital twin of major systems (cabin, HVAC, battery, powertrain) was developed. This enables real-world system-level validation.
#Obj. 2 – Infrared Heating Panels Including Thermal Insulation
Infrared heating panels were installed on the floor and backrests of all 22 passenger seats. Tested in the second campaign with a basic control strategy, they support fast, energy-efficient heating. Cabin and heating system insulation were improved after analysis in the first test. These enhancements led to notable energy savings.
#Obj. 3 – User-Centric Designed HMI
An intuitive HMI was developed for both driver and passengers, running on touch displays. It enables comfort feedback and control of thermal systems. The driver version also offers full HVAC control, including air temperature settings. The design supports energy-efficient, user-responsive climate management.
#Obj. 4 – Optimised HVAC System
A heat pump-capable HVAC system with retained cooling and waste heat recovery was developed. A semi-indirect layout was chosen for optimal efficiency. It uses a direct evaporator and indirect condenser connected to a coolant loop. This enables efficient heating even in very cold conditions.
#Obj. 5 – Optimised Thermal and Energy Management
A predictive control strategy was implemented using a validated digital twin. Nonlinear model predictive control manages HVAC and IR heating while maintaining comfort via the PMV index. Driving behaviour prediction via ADAS and machine learning further enhances efficiency. Battery heating was also optimised to reduce thermal energy use.
#Obj. 6 – Driving Behaviour Prediction
Machine learning models were trained on ADAS datasets to predict short-term velocity profiles. A self-supervised module detects behavioural deviations in real time. Long-term forecasts use map and route data for aggregated driving metrics. These predictions support better thermal and energy planning.
#Obj. 7 – Real-World Range Increase
The project aims for a ≥20% range increase at 0 °C through combined innovations. Initial test campaigns show promising gains from IR heating and insulation. Further improvements are expected with NMPC and battery pre-conditioning in simulation. The final simulative validation will confirm target achievement under real-world conditions.
#Obj. 8 – Cost Reduction at Vehicle Level
Cost savings (>5%) are driven by use of an oil-free e-compressor and modular ECU architecture. These reduce system complexity, part count, and integration costs. Enhanced efficiency may allow for battery downsizing. Together, these contribute to lower total vehicle cost.
#Obj. 9 – Reduction of Development Time
A 30% reduction in development time is targeted using digital twins, model-based workflows, and AI. A calibrated 1D twin enables simulation and real-time validation. Machine learning accelerates controller design, including PMV estimation. MiL and HiL testing front-load development and reduce physical iteration.
Progress on direct impacts against the expected topic outcomes
The innovation activities of this project deal with the improvement of the driving range of an electric minibus by at least 20% at an ambient temperature of 0 °C. This is achieved by introducing a highly efficient heating system based on infrared heating panels, controlled by a novel user-centric HMI, embedding an optimised thermal and energy management strategy for improved comfort and reduced energy consumption. These activities are complemented with the demonstration of a new HVAC unit based on a heat pump, capable of reducing the vehicle’s cooling energy requirements by 15 % against the baseline, while leveraging the efforts made on the HMI and TEMS.
By now the user-centric HMI was defined and implemented on a touch screen. The infrared heating panels were integrated into the minibus and tested at 0 °C ambient temperature on the climatised chassis dynamometer. The optimised HVAC system with heat pump mode was defined and simulations performed. the operating strategy is currently optimised by using the digital twin models of the minibus’ cabin and powertrain models.
Once the results of the final measurement campaign with the optimised predictive energy and thermal management strategy are available, the economic and ecologic impact are available in later stages of the project, the technologic, scientific, societal and economic impacts of the solutions developed in this project can be shown.
Progress on wider impacts targeting zero emission road transport
As already mentioned above, at this stage of the project, it is too early to quantify any impact of MINDED, as not enough results have been generated so far.
Nevertheless, MINDED is on track for delivering an electric minibus with an at least 20% improved driving range at 0 °C compared to the baseline vehicle. The results of MINDED will help accelerating the transformation of road passenger transport to zero-emission through a world-class European research and innovation and industrial system by fostering the close collaboration between one major European OEM for buses, six industry partners, three universities and one RTO. Furthermore, the improved HVAC system together with a user centric HMI will increase user acceptance by enhancing thermal comfort and driving range.
However, as this is the first reporting period only results in parts of the project implementation are available yet. A better assessment of the progress towards delivering scientific, economic, societal or technical impact can be given in the following reporting periods once more results have been generated.
The innovation activities of this project deal with the improvement of the driving range of an electric minibus by at least 20% at an ambient temperature of 0 °C. This is achieved by introducing a highly efficient heating system based on infrared heating panels, controlled by a novel user-centric HMI, embedding an optimised thermal and energy management strategy for improved comfort and reduced energy consumption. These activities are complemented with the demonstration of a new HVAC unit based on a heat pump, capable of reducing the vehicle’s cooling energy requirements by 15 % against the baseline, while leveraging the efforts made on the HMI and TEMS.
By now the user-centric HMI was defined and implemented on a touch screen. The infrared heating panels were integrated into the minibus and tested at 0 °C ambient temperature on the climatised chassis dynamometer. The optimised HVAC system with heat pump mode was defined and simulations performed. the operating strategy is currently optimised by using the digital twin models of the minibus’ cabin and powertrain models.
Once the results of the final measurement campaign with the optimised predictive energy and thermal management strategy are available, the economic and ecologic impact are available in later stages of the project, the technologic, scientific, societal and economic impacts of the solutions developed in this project can be shown.
Progress on wider impacts targeting zero emission road transport
As already mentioned above, at this stage of the project, it is too early to quantify any impact of MINDED, as not enough results have been generated so far.
Nevertheless, MINDED is on track for delivering an electric minibus with an at least 20% improved driving range at 0 °C compared to the baseline vehicle. The results of MINDED will help accelerating the transformation of road passenger transport to zero-emission through a world-class European research and innovation and industrial system by fostering the close collaboration between one major European OEM for buses, six industry partners, three universities and one RTO. Furthermore, the improved HVAC system together with a user centric HMI will increase user acceptance by enhancing thermal comfort and driving range.
However, as this is the first reporting period only results in parts of the project implementation are available yet. A better assessment of the progress towards delivering scientific, economic, societal or technical impact can be given in the following reporting periods once more results have been generated.