Project PISZA: Powertrain Integration for Safe working voltage, net Zero Applications

The purpose of this project is to develop a 48V motor with an integrated drive targeting high power, low voltage markets in the UK and Europe at a competitive price point. Doing so will support SMEs in both the UK and Germany in expanding their operations and accessing new markets as well as supporting the development of the supply chain for these products in both the UK and Europe.

The novelty in this work is a consequence of additive manufacturing of critical components of the electrical drive system, enabling power density levels beyond the state of art. The innovation will result in the manufacture of a first of its kind low-cost high-power integrated drive solution for 48V applications

Small Internal Combustion Engines (ICE) with power outputs extending to 30-40 kW are found in a myriad of applications including but not limited to motorbikes, agricultural and material handling vehicles, excavators, side by side utility vehicles and boat outboards. These ICEs are highly polluting, unreliable and inefficient, contributing significantly to global CO2 and other harmful emissions.

To put this in context CO2 emissions associated with small ICE garden and landscape usage in the USA exceeds the total UK emissions from aviation. The bespoke and diverse application of these small ICEs mean that they are often operated in remote outdoor environments and are maintained by the owner or a local repair shop, making unsafe working voltage (\>60V) battery-electric replacements unviable.

Decarbonisation of the small ICE usage sector is advancing with a range of commercially available drives with ratings up to a few kW. There is an absence of affordable systems at the higher power end of the application and currently, a low-cost \>30kW 48V motor drive doesn't exist to deliver net-zero electric propulsion in the bulk of applications that currently utilise small ICEs.

There is a clear market need for low-cost higher power 48V systems, especially where repairability is a key requirement as it offers a degree of safe serviceability of the entire system including in non-specialist environments.

The existing niche market for this kind of product and the benefits of this intended approach will enable the partners to corner this market. As electrification accelerates over the coming decade, the market will expand rapidly and by developing the capability and supply chain now, the UK will be well-placed to stay at the forefront of the transport electrification agenda.