Supply Chains and Work Packages

 

eDAS is organized in Supply Chains (SCs) and Work Packages (WPs). Every SC is to deliver a demonstrator. The work is done within the WPs. Because every WP takes part in several SCs, information exchange and efficient working is ensured. There are partners, who are in charge of leading a WP or a SC. They are called WP- or SC-leader.

Click on the SCs and WPs to get further information.

 
 

Supply Chain 1 - Wireless Curb Charging

 

Within the eDAS project research activities on several crucial components of an electrical vehicle are bundled together to achieve higher climate robustness for pure electrical and hybrid vehicles.

Supply Chain 1 focuses on wireless energy transmission systems. These systems are commonly known, however the potential that wireless charging offers isn’t exploited yet. Wireless energy transmission within a power range of 5 to 1.000 W and an air gap from 1 to 15 cm has a lot of promising application potential, but research activities with this specification are limited. In fact, wireless energy transmission within this power level is not only beneficial for hybrid cars and EVs, but also for a lot of home and office applications, running in the same power range (see Figure below).

In this context, the Institut für Leichtbau und Kunststofftechnik of the TU Dresden performs research on the calculation techniques for efficiency mapping, as well as on the integration techniques to seamlessly integrate the wireless charging units into structural car parts. These techniques mainly influence the price and the tightly linked market penetration potential of a suchlike system.

By utilizing the power transfer system for thermally condition applications it shall become possible to use more of the battery capacity for traction purposes and less for climatisation. Thus the driving range can be boosted and a predictable driving mileage can be achieved. In combination with the research activities of the battery systems the overall system efficiency can be increased even further.

 

Supply Chain 2 - Innovative accelerated inverter charging

 

Objective

This supply chain will provide the AVL SFR inverter integrated in a test bed which allows the verification of function and software development for advanced inverter charging with wide range of power. In addition a prototype connectivity box to the grid will be developed. The system will be demonstrated in the AVL prototype vehicle.

  

 

Progress beyond state of the art

Today, typically AC charging methods for EVs are using On-board charging devices in addition to the existing powertrain propulsion inverter. In this proposal the powertrain inverter will be used for charging, which will reduce required devices in the vehicle.

 

Expected results and benefits

  • Reduction of vehicle costs, weight, reduction of vehicle cooling system (on-board charger typically needs to be cooled) as well as reduced system complexity.
  • Overall losses generated by using control units are reduced.
  • These effects are combined with a wide range of possible charging power. In general, the sum of these results will increase vehicle mile-range (by e.g. weight reduction).
  • Quantifiable result will be demonstration of advanced charging function on inverter test-bed as well as in AVL prototype vehicle.

 

Supply Chain 3 - Combined energy storage for electrical and thermal energy combined with enhanced energy management

 

Objective

  • Preparing energy storage for advanced usage in the vehicle.
  • Using an innovative material (PCM) the thermal management and related control functions can be improved. By re-using results of other program (battery module with PCM material, Gemac) this SC will provide the control unit (e.g. Aurix IFAG) and the integrated innovative thermal management functionality to operate the battery module on a test bed. The battery test-bed itself will also be provided for usage by AVL -A in this program.

Progress beyond state of the art


Today’s battery pack designs are based on different cooling strategies and functionalities which are key disciplines. Cooling systems and methods have strong impact on the size, cost and efficiency of the battery system. PCM material will be used in battery design and combined with advanced thermal management functions. This goes along with thermal simulation of the system as well as design assessment considering PCM integration.

 

 

 

Expected results benefits

Resulting benefits beyond state of the art will investigated, e.g. possible reduction of cooling system by using advanced functionalities combined with PCM material (cost, size reduction) as well as possible thermal energy distribution advantages (preconditioning, high load) in the vehicle or battery.

 

 

Supply Chain 4 - Common powertrain computer platform

 

Objectives

  • Integration of energy management applications to an overall resource management system for electric and thermal energy (ERM)
  • Provision of a Central Computing Unit (CCU) based on advanced AURIX® multi-core controllers, including in particular a Hardware Abstraction Layer (HAL) and a comprehensive Energy Resource Scheduler (ERS)


 

Description

One of the main tasks of the Supply Chain 4 will be the provision of an open and extensible CCU, hosting and integrating the central energy management applications developed by the eDAS project. The CCU hardware will be based on advanced AURIX® controllers, taking best effort of the powerful multicore architecture and the comprehensive safety features of AURIX®. The work will further include the development of a new Hardware Abstraction Layer (HAL), a comprehensive Energy Resource Scheduler (ERS) and base SW modules (e.g. drives). These components will be integrated together with an OSEK compliant real-time OS (ERIKA®), thus providing the basis for the implementation of the overall Energy Resource Management applications (ERM). The CCU development will further take into account the requirements of other projects, in particular the cluster projects iCOMPOSE and INCOBAT.

 

 

Work Package 3 - Elements of electrical and thermal energy generation, management, storage, recuperation and harvesting

This work package is focused on the design and experimental verification of the concepts developed in the eDAS project. The outcome of this work package will allow to show and to verify the projects' results with developed hardware on a test bench environment. Components like the battery pack, the electrical motor, inverters and chargers, will be engineered to exactly fit the holistic system approach of the project, where electrical, thermal and data flow are actively routed to achieve a significant improvement of the predictability of mileage.

This work package has identified two mobile applications of electrical drive trains, where a predictable mileage is crucial: automotive and aviation drive trains.
The picture below gives a short overview on the aviation drive train. The components addressed for this application are: battery monitoring, battery management as well as an on-board charger.

The diagram below shows the components in the automotive drive train, that will be characterized. This includes a battery system, a combined charger-inverter, a wireless curb side charger and an electrical machine along with an electrical control unit especially developed to coordinate the flow of information, including electrical and thermal energy flows.