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23LOW CARBON VEHICLE SPECIAL EDITION AUTUMN 2016 22 AUTUMN 2016 LOW CARBON VEHICLE SPECIAL EDITION

POWERTRAINPOWERTRAIN

Best practiceAlan Walker and Wilhelm Graupner of AVL discuss the impact of electrification on the powertrain engineering industry

As the world’s largest independent developer of powertrain systems, AVL is at

the forefront of technology innovation for electrified vehicles. With electric and hybrid vehicles increasing in market presence, AVL has added to its traditional work around the internal combustion engine and increasingly significant focus on electrification: both its impact on conventional powertrains and the shift to new components such as battery systems, power electronics, high voltage wiring and the overarching integration of these elements.

Founded in Austria in 1948, AVL has a global reach of over 8,000 employees across facilities throughout the world. Alan Walker, Technical Centre Manager, works from the company’s Coventry development centre with clients from the UK, Europe, and Asia. He explains that within the electrified powertrain sector, the company’s activities in the UK are predominantly around the passenger car with increasing work in motorsport and on or off highway heavy-duty commercial vehicles.

Working with all leading OEMs, in recent years AVL has worked closely with Audi on the development of the car manufacturer’s A1 E-tron hybrid electric vehicle. The central challenge of this project was to achieve a satisfactory range in a very compact EV. AVL’s engineers considered a number of possibilities before settling on a 254-cc single rotor Wankel engine that delivers 15kW and a range of 155 miles on a single battery charge and a 14-litre petrol tank.

Furthermore, AVL has developed

a proprietary analysis tool, E-Drive, that allows vehicle developers to assess drivability in ‘realistic’ virtual environments. “The model helps clients to make some decisions earlier in the development process, such as hardware selection like the size of the electric machine or its position in the vehicle,” says Walker. “It also offers more nuance in the calibration of controls, how the car accelerates, how you want pedals to respond and so on. It’s quite powerful, because you can get feedback from a representative driver before a prototype even exists.”

Left: Alan Walker Right: Wilhelm Graupner

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27LOW CARBON VEHICLE SPECIAL EDITION AUTUMN 2016 26 AUTUMN 2016 LOW CARBON VEHICLE SPECIAL EDITION

SUNDERLANDSUNDERLAND

Leading the wayThe city of Sunderland goes from strength to strength as one of the country’s most significant hubs for low carbon mobility development

Building on the bedrock of the flagship Nissan factory in the city, the European home of

production of the fully electric LEAF and lithium-ion batteries for electric vehicles, Sunderland has emerged as one of the UK’s key hubs for the low carbon vehicle industry. The North East city is home to a number of electric mobility supply chain and infrastructure companies, many of whom are now tackling national and international projects.

“Sunderland is extremely honoured to call itself home to the most productive car plant in Europe and a thriving supply chain that is innovating day-in-day-out,” says the leader of Sunderland City Council councillor

Paul Watson. “We have proudly helped to lead the way when it comes to the LCV market, with the world’s best- selling zero emission one hundred per cent electric LEAF coming out of our great Nissan plant here in Sunderland, as well as the production of lithium-ion batteries for electric vehicles.”

“This all lays the foundations for Nissan’s vision for a greener, cleaner and more sustainable future through their intelligent mobility vision and Nissan Futures - with vehicle-to-grid technology. And, with our Low Carbon Enterprise Zone we are creating the conditions for smaller niche companies in the sector to grow too,” he continues.

Last year this magazine reported that battery specialists Hyperdrive had opened a production facility in Sunderland. Production at the site continues to grow and at the 2016 Cenex LCV event Hyperdrive is to announce the launch of its new 48V lithium-ion battery packs, which are scalable to serve automotive, off-highway and autonomous vehicle applications.

Ultimately, the company’s goal is to supply technology onto every electric vehicle and hybrid electric vehicle in the world. The new Li-ion product range brings together proven battery management technology (developed in-house) with cells made in the UK by neighbour Nissan to

enable carmakers – including OEMs and niche vehicle manufacturers – to electrify powertrains, cutting emissions with the help of Hyperdrive’s world-class engineering team.

Hyperdrive has attracted multi-million pound investment this year and is working with vehicle manufacturers, Tier One suppliers, battery cell developers, and utility providers to commercialise new systems, including energy storage technology that could dramatically cut the payback time for domestic investors in renewable energy technology such as solar photovoltaics.

“At our new production facility we have invested to increase the level of automation as we are looking to triple our output across a number of product lines,” says Hyperdrive business development manager Steve Abbott. “As a company we are growing really quickly – this year we will double revenue again and we now have 30 staff which again is almost double what we had a year ago.”

The company is already working with Innovate UK and the Advanced Propulsion Centre to develop advanced lithium-ion automotive technologies for automotive and off-highway applications. It is also working on advanced electric systems for robot factory automation. With Innovate UK, the firm has successfully completed projects to convert petrol-engine vehicles to electric cars, adding unique range extender technology, as well as providing the powertrain and battery pack for a long-endurance, autonomous marine craft used for surveying and defence applications.

Meanwhile on the infrastructure side, charging specialists Elm EV are also expanding. The company

supplies vehicle charging infrastructure to public and private sector clients, managing the installation and operational support of the devices.

Elm EV founder Dan Martin explains that whilst the core of the business was developed around public sector contracts (installing charging points for NHS Trusts and local authorities), there has been a noticeable increase in private sector activity in the recent year. “We are seeing increased growth with private sector clients as large fleet managers and companies are starting to realise that by adopting EVs they will not only save a lot of money but

will be able to meet carbon reduction targets,” he says. “We are starting to see the industry become more competitive and it is an exciting time.”

In addition to its Sunderland base, Elm EV has offices in London and Bristol, allowing the company to tender for contracts throughout the country. Elm offers clients a range of ownership options including direct installation of the charging device to leasing solutions and concession charging models. The company works closely with major charging equipment manufacturers, including DBT and ABB, to ensure that its clients are able to select the

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