RECONFIGURABLE LIGHT ELECTRIC VEHICLE

Project Information

REFLECTIVE

Grant agreement ID: 101006747

DOI

10.3030/101006747

Project closed

EC signature date 6 November 2020

Start date 1 February 2021

End date 31 October 2024

Funded under

• SOCIETAL CHALLENGES - Smart, Green And Integrated Transport

Total cost

€ 7 508 348,44

EU contribution

€ 5 981 056,25

Coordinated by

TEKNOLOGIAN TUTKIMUSKESKUS VTT OY
Finland

Periodic Reporting for period 2 - REFLECTIVE (RECONFIGURABLE LIGHT ELECTRIC VEHICLE)

Reporting period: 2022-08-01 to 2024-10-31

Summary of the context and overall objectives of the project

Urbanisation and rising transport emissions demand cleaner, efficient transport. The European Green Deal aims for a 90% reduction in transport emissions by 2050 and the development of sustainable mobility services and infrastructure.
The Reconfigurable Light Electric Vehicle “REFLECTIVE” aimed at introducing an L7e category light vehicle concept that could be safely, conveniently, and efficiently operated in various urban environments and missions. On a higher level, our objectives were to mitigate the negative effects of vehicles on the global environment through electrification, rightsizing, and intensification of vehicle usage. Simultaneously, our concept aimed to make moving in cities and urban areas more convenient.
Our first technical objective was to propose a powertrain configuration that could be easily adaptable from L7 to M1 category vehicles. The powertrain was to be rightsized for urban missions, both in terms of installed power and energy capacity. Through further optimisation of energy management, a total 10% decrease in energy consumption for typical urban profiles was aimed at. The second technical objective was to increase the passive safety of L7 category vehicles remarkably without losing the adaptability of the vehicle to different urban use cases, from the transport of people to the transport of goods. Third, we aimed at improving the overall usability and attractiveness of the concept via charging flexibility and limited automated features, for instance, for parking or charging. The fourth technical objective was to test the REFLECTIVE vehicle both in laboratory environments and traffic to validate its efficiency, usability, and safety. Lastly, we aimed at communicating and disseminating the project results as widely as possible to different audiences to gain feedback and, importantly, to promote the outcomes of our project and their market uptake.

Work performed from the beginning of the project to the end of the period covered by the report and main results achieved so far

The REFLECTIVE project generated significant research results towards its technical objectives:
Powertrain development: The REFLECTIVE Light Electric Vehicle (R-LEV) powertrain was developed, integrated into the vehicle, and subsequently tested within the vehicle. An induction traction motor was developed during the project. The Vehicle Control Unit (VCU) hardware was procured off-the-shelf, while its control algorithm was fully developed in-house. The powertrain components are designed to support scalability from L7e to M1 category vehicles and can be modified to meet higher power requirements. The powertrain achieved a maximum energy efficiency of 88%, with an expanded high energy efficiency operational regime.
Structural safety and flexibility: Through intensive design and structural optimisation activities, significant improvements in safety and flexibility were achieved. The R-LEV underwent crash testing and attained a performance equivalent to a Euro NCAP four-star rating according to the L7e testing protocol. The vehicle’s interior design supports various urban use cases, featuring removable rear seats to accommodate both passenger and cargo-focused operations. This flexibility enhances the vehicle’s utilisation possibilities.
Automated features and charging: REFLECTIVE promotes the flexibility of electric vehicle usage by offering both conventional conductive and wireless charging options. Both charging systems were tested and successfully integrated into the R-LEV. Additionally, an Automated Driving System (ADS) was developed, tested, and integrated, enabling the vehicle to automatically relocate to the wireless charger ground unit and start the charging.
Validation and testing: All solutions were rigorously validated through both laboratory and real-life experiments. These tests demonstrated the functionality and energy efficiency of the powertrains, ADS features, user-friendly conductive and wireless charging systems, and crash safety performance equivalent to Euro NCAP 4-5 stars. During real-life testing in Finland, the average energy consumption was measured at 116 Wh/km, while the energy consumption charged from the grid was recorded at 135 Wh/km.
Dissemination and exploitation: The REFLECTIVE research results were disseminated through publications in scientific journals, conference proceedings, and sector magazines. The project actively participated/organised in international events and workshops focused on sustainable mobility and launched a final Video News Release. A final event, open to all interested parties, was organised in October 2024, showcasing the vehicle prototype. Options for exploiting the results were explored, including an analysis of the Intellectual Property Rights (IPR) generated by the project partners.
In conclusion, the REFLECTIVE project generated various results that present a highly advanced electric heavy quadricycle. The technical and other objectives of the project were largely met.

Progress beyond the state of the art and expected potential impact (including the socio-economic impact and the wider societal implications of the project so far)

The following advancements beyond the state-of-the-art were achieved during the REFLECTIVE project:
Realistic driving and duty cycles: Utilising the VTT Smart eFleet tool, realistic driving and duty cycles were developed for light electric vehicles, facilitating the rightsizing of the vehicle and its powertrain for various urban use cases and missions.
Efficient and scalable induction traction motor: An energy-efficient induction traction motor, free from critical raw materials, was designed, resulting in reduced costs. The motor and its control unit are scalable from L7 category to M1 category vehicles. The liquid cooling solution allows for different mounting positions, enhancing its flexibility.
Charging: The REFLECTIVE vehicle incorporated both conductive and wireless charging options, enabling operations in diverse settings and infrastructures.
ADS: As an optional add-on performance and safety kit, the ADS was successfully utilised within the project for automated relocation to the wireless charging ground unit and initiating the charging event.
Thermal management for energy savings and user comfort: The battery could be heated with cabin air during driving and charging and cooled with air from the HVAC unit. Additionally, heat from the powertrain cooling circuit could be used to warm the cabin in winter, reducing the power required for the PTC heater. This strategy also involved optimising heat recovery from the powertrain and bypassing the main radiator to maintain optimal component temperatures and reuse energy for cabin heating.
Structural optimisation for increased safety: Compared to market L7e vehicles, which typically achieve a maximum of two Euro NCAP stars, the R-LEV outperformed them by attaining a performance equivalent to a Euro NCAP four-star rating according to the L7e testing protocol. This achievement can significantly enhance the acceptance of small vehicles among users.
Adaptable interior design: The interior design of the REFLECTIVE vehicle was made adaptable to various urban use cases, featuring removable rear seats and add-on ADS. Capitalising on this feature could lead to significantly higher utilisation rates than currently observed for smaller vehicles.
Recommendation for a new vehicle category: Our proposal is to create a new Category “L8e” that can provide this utility purpose to the end user by combining both sub-subcategories and potentially more if needed. From a homologation perspective, a specific study of the requirements should be conducted to determine each parameter and its limits for the proposed new category.

REFLECTIVE workshop at Spazio Europa room, Italy

REFLECTIVE face to face meeting at IDIADA, Spain

REFLECTIVE flyer

REFLECTIVE L7 vehicle sketch

REFLECTIVE logo