EM-TECH: Smart e-corner and Smart e-axle assembly (D6.1)

1.1 Overview of project

The EM-TECH project is advancing electric machine technology for automotive application through innovative solutions designed to enhance performance, sustainability, and efficiency. The project focuses on advanced cooling systems, real-time virtual sensing, optimized machine control strategies, electric gearing for operational flexibility, and digital twin-based design incorporating life cycle considerations. Additionally, it promotes sustainability by utilizing recycled permanent magnets and circularity-driven approaches in electric machines and related powertrain elements. These project components will power next-generation radial flux direct-drive in-wheel motors and axial flux motors, delivering competitive torque and power densities. Targeting passenger cars and vans, with scalability to commercial vehicles, the project aims to reduce energy losses, cut reliance on rare earth materials, and integrate magnet recycling for an affordable and eco-friendly future in electric mobility.

1.2 Deliverable Objective and Results

D6.1 focuses on the integration and testing of two advanced powertrain components: the smart e-corner and the smart e-axle. The In-Wheel Motor (IWM) from ELA is integrated into the smart e-corner at TUIL and the baseline On-board Axial Flux Motor (AFM) is mounted on the powertrain test rig at USR. In parallel, a smart e-axle will be implemented at USR, while the dSpace Scalexio Rapid Prototyping system at TUIL will operate a virtual Vehicle model within a X-in-the-Loop (XiL) framework. This setup allows for distributed real-time simulation and control across both sites.

The experimental configurations will be equipped with comprehensive instrumentation—voltage, current, torque, temperature, and vibration sensors—to measure electrical and mechanical performance, thermal behaviour, and Noise, Vibration, and Harshness (NVH) characteristics. Control and monitoring will be coordinated through the dSpace platform and through a secure Virtual Private Network (VPN) connection between USR and TUIL. This work will result in Deliverable D6.1.