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Quantum secured electrical electronicarchitectures: Vehicles, factories and supply
chains
Pietro Perlo, Director, I-FEVS
Electrification is the main growth driver of the market and it is re-shaping the industry with New Players, New Businesses and New Service-based Models
MARKET REQUESTS• Safety first• Small EVs: Four/three/two wheels• Affordable prices and low Total Cost of Ownership• High connectivity level with high security level• Personalization
MANUFACTURING NEEDS• Low investments • Flexibility and multipurpose platforms • Blockchain certified “Made in Portugal, Italy, Poland…”• High convergence with renewable energies: V2H, V2G..
Changing needs
Urban Mobility Opportunities
Operators• e-Bikes the most widespread: +50 Millions yearwith a further CAGR of 5-7% for the next 5 years
• The highest CAGR is registered for small three(India >800,000 e-rickshaws in 2017) and smallfour wheel vehicles (China 2.1 Million Low SpeedEVs produced in 2018). Including ASIAN a 50% to70% CAGR in the next 5 years is likely,
• Japan the first country experiencing urbanconcentration, today about 40% of vehicles inthe roads are Kei-cars
Vehicles• GM’s $500M invested in Lyft and owns Cruise Automation • BMW’s ride-sharing service, ReachNow• VW’s $300 million investment in Gett• Tesla going to its own ride-sharing platform• Toyota Motor Corp. has backed Uber for an undisclosed amount• Daimler owns Hailo, MyTaxi, Taxibeat, and Ridescout• Ford acquired shuttle service Chariot and bought a majority stake in Argo.AI for $1B
Complexity of current design
• Complexity of moulds to shapemetal sheets in a 3D geometry
• Complexity of tooling toassemble/weld the moulded components
• Lack of flexibility to reconfigure thestructure: great difference betweenchassis with one and two doors
• Large production volumes necessaryfor acceptable ROIs.
• A large scale mfg line costs >100 M€
Complexity of current manufacturing
Challenges
q Electric Vehicles must be Born Electric1
q New companies thinking they can compete with the traditional OEMs on their technologies are BornDead2 companies. (October 2019 Dyson has cancelled its plans to build an electric car, claiming the project is «not commercially viable3»).
q Transforming a conventional Factory into an Industry 4.0 environment is a nightmare
q Transforming an Industry 4.0 into an AI 4.0 environment is another nightmare (The data and the full environment have to be preparred for a Fully-distributed AI with lifelong on-device learning).
q New Factories must be Born AI 4.0.
1 P.Perlo at idtechex San Josè 2010. https://www.printedelectronicsworld.com/articles/2898/new-revelations-at-future-of-electric-vehicles-san-jose2 http://docplayer.net/84835549-Evolving-towards-collaborative-manufacturing-pietro-perlo-i-fevs-torino-e-district-non-profit-research-organisation.html3 https://www.theguardian.com/technology/2019/oct/10/james-dyson-scraps-plans-to-build-electric-car
Manufacturing: The Challenge
Develop a production environment capable of:
• Flexible manufacturing implementing Industry AI 4.0 technologies• Low cost investment• Automotive grade suppliers• Best in class vehicles for safety and performance
• Best in class vehicles and plant for implemented level of security
Microfactory co-developed with Comau
The Output
The vehicle architecture
Minimal changes in the chassis to manufacture in a flexible and agile way a variety of vehicles.
Designs worldwide patented.
Crash Tests
Safety tests performed for all vehicle architectures
From More Than One Year To Minutes
Design, Construction of Moulds, Stamping, Robotized line assembly… >> 1 year
H2020 DEMOBASE project: AI driven design ofchassis: few minutes - no moulds - no stamping -no robotized assembly - Ultra simplified templatesfor a Quasi Self-assembled chassis meeting fullfrontal, off-axis and lateral crash tests.
The vehicle family
FOCUS
Scope:• Micro-factory for multi-model portfolio• Entire plant co-development• Design for manufacturability• Standard solution for easy replication
Flexible and AgileProduction Plant
Benefits:ü Partnering from concept product design to
vehicle production launchü Scalability: from manual to fully automatized
solutionsü Station Modularity and easy re-configurability
Technologies and Innovations:ü Welding, fastening, vision systems
ü In-line testing and quality gates
ü Industry 4.0 architecture
Middleware
MES
S S S
Working Island
Cloud Services
Management
VISUALIZATIONSUPPLIERS
R&DMAINTENANCE
Legend:
Standard Interfacefor Service
Tool
S
KPIs monitoring & visualization
Scheduling
Chassis testPowertrain test
I/O linkMaster
HMI
S
IOT Container
S
Machinery
S
Shopfloor Customer App Model Chooser
I-FEVS: Ind 4.0 microfactory
I-FEVS Quantum secured Ind4.0 microfactory
