Thermal and energy Management for INcreased Driving range of an Electric minibus including improved user-centric Design and thermal comfort

MINDED addresses in full the “expected outcome” and “scope” of the HORIZON-CL5-2023-D5-01-01 topic by delivering a battery electric IVECO eDaily minibus with 20% improved range at 0°C against the 2023 baseline.

This is achieved by introducing a highly efficient heating system based on infrared (IR) panels, controlled by a novel user-centric HMI, embedding an optimised thermal and energy management strategy (TEMS) for improved comfort and reduced energy consumption.

These activities are complemented with the demonstration of a new HVAC unit based on a heat pump, capable of reducing the vehicle’s cooling energy requirements by 15% against the baseline, while leveraging the efforts made on the HMI and TEMS.

To do so, MINDED encompasses 10 Technology Bricks, organised in three AREAs:- Heating and Cooling System (AREA I), including (1) IR heating panels, (2) thermal cabin insulation, (3) a thermal mannequin for evaluating passenger comfort, (4) the optimised HVAC unit featuring an e-compressor with gas bearings, (5) the required ECUs, and (6) the user-centric HMI.- Digital Twin and Control Strategy (AREA II), including (7) a new digital twin model, (8) an AI-based algorithm for predicting driving behaviour, (9) the TEMS, and (10) a comfort control strategy for determining optimal settings.- Demonstration and Performance Evaluation (AREA III), demonstrating the IVECO eDaily minibus on the dynamometer at TRL7 and the HVAC unit on the ThermoLab testbed at TRL6.Beyond the range improvement, MINDED demonstrates a cost reduction of 5% at vehicle level from simplified systems’ installation and reduced battery requirements, and a development time reduction of 30% achieved using the digital twin model and AI.

The project generates its primary impact in the bus and minibus vehicle segments, with the MINDED Technology Bricks expected to equip 75% of the IVECO bus fleet by 2035, while delivering technologies exploitable in the medium/heavy commercial electric vehicles market.