Transport related emissions and urbanisation are creating an unparalleled demand for less polluting and efficient means of moving. Tackling the challenge is imperative and it calls for comprehensive understanding of the landscape, its every aspect and innovative mindset. It is a well-known fact that electric vehicles are a big part of the solution (combined with renewable energy production). We aim at developing and demonstrating an innovative, modular vehicle concept that is just perfect for the urban needs: zero emission, compact, safe and rightsized for the mission. Furthermore, we aim at intensifying the utilisation of the vehicles through versatile designing to promote, e.g., multipurpose usage and shared concepts. The key technical innovations of our RECONFIGURABLE LIGHT ELECTRIC VEHICLE, REFLECTIVE, vehicle are: 1) modular, scalable, electric powertrain and reconfigurable interiors fit from L7 quadricycles to M1/A vehicles; 2) supreme structural and active safety proven in Euro NCAP crash test and real life experiments of our L7 demonstrator vehicles; 3) added usability and comfortability through adaptable charging solution combining conductive and wireless charging and limited automated features. To conclude, we aim at introducing a L7 demonstration vehicle that meets the highest quality and safety standards with an affordable price making it an irresistible choice for any urban environment and use case. No such solution exists at the market and our primary aim is to bridge this gap.

The core objective of InnoBMS is to develop and demonstrate (TRL6) a future-ready best-in-class BMS hard- and software solution that maximizes battery utilization and performance for the user without negatively affecting battery life, even in extreme conditions, whilst continuously maintaining safety. Concretely, the InnoBMS proposal will deliver a 12% higher effective battery pack volumetric density, a 33% longer battery lifetime and a demonstrated lifetime of 15 years. The results will be demonstrated using novel testing methods that give a 36% reduction in the testing time of a BMS. The results will be demonstrated in two use cases, one light commercial vehicle (Fiat Doblo Electric) and one medium-duty van (IVECO eDaily). The key outcomes will enable a cost reduction of 12% and 9.7% for passenger cars and light-duty vehicles, respectively. The core objective will be achieved through five technical objectives. 1) advanced hybrid physical and data-driven models and algorithms to enable a flexible and modular BMS suitable for a wide range of batteries. 2) Software for a fully connected and fully wireless BMS that acts as a communication server inside the vehicle E/E-architecture, the center of connection, on-board diagnostics and decision-taking for all battery-related information. 3) A scalable, fully wireless and self-tested BMS hardware that enables using different battery sizes at different operating voltage levels, and smart sensor integration. 4) Better battery utilization and exploitation using cloud-informed strategies and procedure. 5) A heterogeneous simulation toolchain and automated test methods. The consortium includes 2 vehicle manufacturers, 2 TIER1 supplier, 3 engineering companies, 2 universities (leading in e-power and electromobility), an RTO and 3 SMEs. The partners have worked together closely in previous and ongoing projects, and have extensive knowhow in taking the step from new technology to innovative vehicles for real-world applications.

The EU aims to become an economy with net-zero greenhouse gas emissions, achieving climate neutrality by 2050. Batteries will enable this clean energy transition by helping to decarbonise transport and enabling a higher uptake of renewable energy technologies. Therefore, the electrification of the European economy and society, both in transport and stationary storage sectors, has resulted in an expensive growth of the European battery industry (from battery cell manufacturers to recycling and second use companies). Achieving optimal utilisation of battery systems (by increasing the operational and lifetime usage window and reducing cost via a more efficient and appropriate use of materials) benefits not only the environment but also the end-users. The overall NEXTBMS aim is to develop an advanced battery management systems (BMS) built on fundamental knowledge and experience with the physicochemical processes of lithium-ion batteries, which will enable the significant enhance of current modelling approaches, including the readiness for upcoming lithium (Li) battery material developments. These modelling approaches will be further improved by optimising sensors and measurement techniques to meet modelling needs (and optimising models based on physical sensor data) and the physical cell configurations to form a framework that supports improving the battery state prediction and -control. By solving these challenges, NEXTBMS will ensure that the next generation of BMSs will enable higher performance, safety, and longer lifetime of the battery cells for an overall optimal utilisation of the battery system. As the NEXTBMS results aim to be implemented in a large variety of the transport and energy storage sectors, the project has a wide market potential to impact and revolutionize the entire battery market and to contribute in achieving the Green Deal objectives.

SYS2WHEEL will provide brand-independent components and systems for integrated 3rd generation commercial battery electric vehicles (cBEVs) for CO2-free city logistics. High efficiency, performance, packaging and modularity enable efficient integration. Mass production costs of e-powertrain components and systems will be considerably reduced, while eliminating negative impact on drivability, safety and reliability. The same components and systems shall be used for different commercial vehicle categories, sub-categories and brands, in urban and inter-urban applications. The project will foster the transition to a broad range of cBEVs and will accelerate market penetration of e-powertrain components and systems. SYS2WHEEL will demonstrate its results on N1 and N2 cBEVs and assesses the related potential for the whole range of L and N category cBEVs as well as extensions to M1 and M2 passenger carriers. Essential enabling elements in SYS2WHEEL are e-motors for both, in-wheel and e-axle systems, a novel suspension for in-wheel systems, the in-wheel and e-axle systems themselves, time-sensitive networking, advanced controls, affordable and efficient processes, as well as scalability/ transferability of innovations. Specifically SYS2WHEEL will reduce costs in mass production by at least 20% through components becoming obsolete and reduction of wiring costs due to application of time-sensitive networks. The powertrain efficiency will be increased by improved e-motor windings, advanced rare-earth magnets, reduced powertrain rotating parts, reduced losses, advanced controls and weight reduction. Affordability, and user-friendliness will be addressed by enhanced modularity and packaging, automotive quality by advanced fail-operational safety and ISO 26262 compliance, modular and scalable technologies and lowered total cost of ownership. Space-saving approaches in SYS2WHEEL lead to more freedom for batteries, cargo and drivers.

Within this project a new compact and efficient high speed 30-50 kW electrical machine will be integrated with an efficient fully SiC drive and a gearbox within a powertrain traction module. The electrical machine will have a dry rotor direct liquid cooling system integrated with the cooling system for the SiC drive. This traction module can be mechanically coupled with an axle of a low performance electric/hybrid vehicle, or several units could be coupled directly with the wheels for a high performance vehicle or a light-duty vehicle or a bus. Economic feasibility of mass-manufacturing of different electric machine topologies will be studied to choose the best trade-off between performance, manufacturing cost, and efficiency in the selected performance range. Feasibility of direct drive, single stage, and two-stage switchable high speed gearboxes will be studied as well. The resultant powertrain traction module will be an optimal trade-off between efficiency, manufacturability, and cost, utilizing newest technologies in electrical machines, power electronics, and high speed gearboxes. We will demonstrate the scalability of the solution by embedding several powertrain modules on board a test vehicle.