Perseus – ICE to EDU
Project challenges
In 2020, UK Government published its 10-point climate change plan, which announced that from 2030 new cars and vans powered by petrol and diesel will no longer be sold in the UK as part of the push towards net zero.
For the automotive industry, this seismic shift brings with it several obstacles that need to be overcome to integrate new, innovative powertrain technologies into existing production landscapes as well as leveling up the supply chains to meet the future demand from the mass market for electric vehicles.
Business challenge
Product Innovation
Process Innovation
Sector
Electrification
Technology or capability
Product Design
Process Design
The Challenge
Jaguar Land Rover (JLR) are reimagining the future of modern luxury and it announced in 2017 its commitment that every Jaguar and Land Rover launched from 2020 would have electrified models available as part of its push towards ‘Destination Zero.’
In November 2018, the successful JLR-led funding bid for project PERSEUS was announced, aimed at supporting the manufacturer and wider supply chain in transitioning to a flexible internal combustion engine (ICE) and electric drive unit (EDU) production line to address the variability in electric vehicle uptake in the UK. The successful bid was part of the Advanced Propulsion Centre (APC) 11 “Advancing the UK’s Low Carbon Automotive Capability” competition.
The consortium JLR built with seven partners, including the MTC, aimed to prepare the existing ICE facility to become a flexible manufacturing line for ICE and electric vehicle (EV) production. Once complete, the adapted facility would allow JLR to ready for the changing product range and retain a customer demand focus.
During the project in 2020, UK Government published its 10-point climate change plan, which announced that from 2030 new cars and vans powered by petrol and diesel will no longer be sold in the UK as part of the push towards net zero.
For the automotive industry, this seismic shift brings with it several obstacles that need to be overcome to integrate new, innovative powertrain technologies into existing production landscapes as well as levelling up the supply chains to meet the future demand from the mass market for electric vehicles.
MTC’s Solution
MTC, working in collaboration with JW Froehlich, Mapel, HSSMI, Horizon Instruments, Fives Landis, Birmingham City University, all guided by JLR began the PERSEUS project with in-person meetings, facility tours and workshops. At the start of the pandemic the consortium successfully transitioned to virtual conferencing and increased the use of digital platforms; demonstrating the same flexibility needed to deliver a flexible ICE-EV production line.
The project aimed to break down every component of the electric drive unit (EDU) and MTC were able to advise on the manufacture and assembly processes including optimisation approaches. An important early phase of the project was the component-specific technology surveys focusing on the EDU.
These studies identified equipment, suppliers and enabled cross-consortia knowledge sharing, thereby upskilling all project team members involved. This would later be the starting point for MTC’s in-depth supply chain mapping study on the state of the UK, EU and international electric vehicle supply chain. The aim of the study was to look at the current capabilities as well as the knowledge gap to be able to build a greater understanding of the automotive sector and place MTC at the forefront to advise on its future.
This newly developed knowledge of the UK supply chain, in addition to existing strategic enablement expertise, was shared to create an all-encompassing strategy for JLR to transition to a fully flexible production line, whilst also developing an understanding of the UK automotive supply chain capability, to increase the knowledge of the consortium.
This supported the significant undertaking by MTC project team, who provided knowledge transfer amongst the consortium, senior leadership teams and the wider workforce to build their understanding of power electronics and e-machines to ensure that they could then engage with the common language required to drive progress on the project.
To ensure a transition to EDU production was possible, consortium partners utilised the Advanced Propulsion Centre (APC) funding stream to develop their equipment and tooling through simulation, prototyping, physical trials, and knowledge transfer.
The JLR led consortium collaboratively reviewed the existing EDU design, highlighted practical issues, identified ICE-EV cross-over points for existing equipment and created solutions for this complex challenge. Threaded throughout the project was an EV supply chain review conducted by the MTC, showing the huge UK manufacturing potential and existing growth opportunities to tap into.
To further our commitment towards Destination Zero, we wanted to use the PERSEUS project to continue to lead the way by advancing the electrification of one of our UK manufacturing facilities. The transfer of knowledge from the team at the MTC, and other partners, and specific deliverables of this project have been vital contributions in our preparation for manufacture of key BEV powertrain components. Ultimately this work has greatly strengthened our position as we seek transition to EV powertrain production and helped move us towards the ultimate target of full electrification.’
Debora Mazzetta, Engines, Batteries and Drives Manager, Jaguar Land Rover
The Outcome
The PERSEUS project brought together teams of experts from multiple disciplines supporting to work across the multiple work packages. This JLR led consortium successfully overcame the challenges presented over the course of the project, from pandemics to re-designs through to demonstrator manufacture delays.
A key aspect of the PERSEUS project involved the development of optimal component process flows to aid in factory floor planning, which were used to complement HSSMI’s Production Line simulation models. This aimed to avoid costly investments in new equipment, the PERSEUS project team worked to establish which aspects of the existing manufacturing capability and equipment could be repurposed for EDU production, whilst also retaining the capability to manufacture ICEs.
Through the extensive technology surveys, not all the initial existing technology was found to be supportive of a flexible production line. This opened the door to other equipment and technologies including adaption of existing laser processing equipment for novel EDU applications. MTC leaned on its internal laser processing team to join the project to assess concepts and conduct trials as part of the development work.
MTC was able to support members of the consortium build custom machinery, alongside their own demonstrators, including a new special purpose conductor-forming machine. Designed to validate essential modelling and simulation, and further explore the unit’s thermal and electrical conductivity capabilities that will ultimately lead to enhanced EDU performance. These demonstrator pieces can be seen in the electrification area of the MTC workshop.
Regular information sharing sessions amongst the consortium enhanced the knowledge transfer aspect of the project, as well as supporting Birmingham City University in the
development of Continuous Professional Development (CPD) courses for other staff within the partnering companies. These courses were created with the overall aim of targeting upskilling across the automotive industry with the rise of electric vehicle manufacture; the CPD courses are anticipated to launch to industry access in 2022.
MTC also completed a thorough supply chain analysis and obtained a wider understanding of the capabilities within the supply chain for electric vehicles. Subsequently this exercise has given MTC a detailed understanding on the challenges faced and the next steps to prepare the UK automotive industry for a future powered by electric vehicles.
Benefits to the Client
The work of the PERSEUS project has enabled the following to be achieved:
- The consortium and key stakeholders at these organisations have enhanced their knowledge of Electric Drive Units, enabling these organisations to better position themselves for the future.
- Road test a new set of Continuous Professional Development (CPD) courses alongside other consortium members, created by BCU. Expecting to be launched to the wider industry in 2022. [ref: The PERSEUS project - School of Engineering and the Built Environment | Birmingham City University (bcu.ac.uk)]
- JLR better understands what it needs to do to prepare for the transition into an EDU production line and fully flexible facility.
The project benefits were not limited to the consortium. The direct results of the UK Supply
Chain Mapping Study have been shared with APC to create a heightened understanding of the current state of the electrification and electric vehicle supply chains. This should enable future funding to be targeted at the key areas for UK manufacturing. Key aspects of the study included:
- The current potential of the supply chain.
- Insight directly from industry on what needs to be addressed to be able to cope with the increasing mass demand for EDUs and electric vehicles.
- How to future-proof the supply chain by methods such as strategic enablement, knowledge transfer and upskilling.
The knowledge and expertise developed by MTC is not only transferrable across the UK’s Automotive Sector, but also to other sectors in the quest to minimise their carbon footprint by adopting electrification technologies. Involvement in this project has placed the MTC as a thought-leader for the manufacturing technologies required for industrialisation and scale-up of production of Power Electronics, Machines and Drives (PEMD) within the UK.
The APC is proud to have supported a project that prepares the UK’s manufacturing capability for the net-zero future. The PERSEUS project has enabled Jaguar Land Rover and manufacturing equipment suppliers to investigate, develop, and prove out processes that allow engine facilities to convert to making electric drive units. The consortium of companies delivering the PERSEUS project have collaborated to build relationships, develop knowledge, and secure UK jobs.
Dan Fung, Head of Strategy and Planning, APC UK