C/O CenexAdvanced Technology Innovation Centre5 Oakwood DriveLoughborough University Science & Enterprise ParkLoughboroughLeicestershireLE11 3AQ

Tel: 01509 635 750Email: nvn@cenex.co.uk

www.nichevehiclenetwork.co.uk

INNOVATION THROUGH COLLABORATION

Introduction

The Niche Vehicle Network (NVN), is an independent association of niche vehicle manufacturers, specialist technology companies, system suppliers, research organisations, design and engineering companies, collaborating on the application of innovative technologies in specialist vehicle development and production. We currently have over 1,100 members.

Through strategic funding, NVN aims to promote and stimulate R&D collaboration and partnership working to support the growth of UK niche vehicle manufacturers and their UK supply chains, safeguarding and creating jobs and skills.

Backed by Innovate UK, the Office for Low Emission Vehicles (OLEV), and the Advanced Propulsion Centre (APC), NVN provides funding to support collaborative research and strategic development activities in the adoption of low carbon vehicle technologies, including electric and hybrid propulsion, advanced battery systems, lightweight body and chassis structures, alternative propulsion systems and aerodynamics. Our programme plays a significant role in promoting the adoption of vehicle electrification and enabling technologies.

Showcasing of Innovation

The Network provides members with the opportunity to showcase their capabilities to the industry at a variety of industry events, notably Cenex-LCV and Advanced Engineering, as well as at OEM showcasing events. These events provide members with the opportunity to meet potential customers and collaborators, as well as engaging with the wider industry.

Some quotes from recent events

“The JCB showcase of capability was a really great event with exposure to the right people. We had the chance to meet with some senior members of staff and some very influential people.” - Penso

“I came away with some serious leads, from new and existing clients. The Advanced Engineering Show offered a good chance to broaden my knowledge too. The show seemed to be very well attended with a large number of visitors approaching the stand until the close.” - Printed Motor Works Ltd

“Interest generated at Autosport International was encouraging in terms of sales with good publicity and exposure. The show was also an excellent networking opportunity.”- Bowler Manufacturing Ltd

Member Networking

The Niche Vehicle Network hold a number of events throughout the year which focus on providing networking opportunities to members. The Niche Vehicle Symposium and Member Forum events provide members with the environment and opportunity to engage with other members.

Some quotes from recent events

“As ever, the Members Forum had a very good spread of presenters, useful, informative with potential for a two-way follow up.”- CAVT Ltd

“The Symposium was excellent, well organised, entertaining and informative.” - Arkwright Scholarships Trust

“The Silverstone UTC was a fantastic venue with great networking opportunities.” - 2 Spec Design

“It was very interesting to see the growth of the Niche Vehicle Network at the Symposium. The new contacts will be invaluable to our progress.” - Riversimple

RotorEmoto

The project aim was for the consortium to assemble a vehicle level proof of concept – specifically to build a “proof of concept” hybrid motorcycle, based around the A2 category.

The project successfully demonstrated hybrid functionality, together with an overall improvement in battery technology (energy density, charge/discharge rate) - key in making a full hybrid motorcycle feasible.

FAST Titanium and RapiComp Carbon Fibre Composite Roadwheel

The project aim was to successfully design, develop and manufacture an ultra-lightweight titanium and carbon fibre road wheel, bringing together two NVN developed technologies (FAST titanium and RapiComp carbon fibre) and to make the concept available to Niche Vehicle Network manufacturers and suppliers.

Combining both technologies was a success. The project scope was met with a circa 50% reduction in mass and inertia when compared to an alloy equivalent. The titanium centre and carbon fibre barrel was manufactured, assembled and leak tested resulting in a successfully produced wheel assembly.

Efficient Heating and Cooling for Zero Emission Vehicles

This project has developed a ‘first-of-a-kind’ integration of an efficient reversible heat pump for buses with a zero-emission fuel cell system. Testing will determine the viability and benefits of electrical, thermal and control integration of the two systems.

The heat pump and fuel cell system were integrated successfully. The FCS control strategy is also robust enough to manage current transients from the heat pump during normal operation. System integration has shown benefits to both systems when FCS waste heat is harvested by the heat pump.

Ariel Lightweight Electric Cycle (ALEC)

The objective of the ALEC project was to transfer technology from niche automotive into the electrified cycle market.

Automotive technology was applied to the battery and electrical systems to deliver a step change in integration and rider controls. Advanced automotive manufacturing technology provided lower weight, improved ride quality and cost down opportunities against current niche bicycle manufacturing processes. The project used this technology to deliver an electrified cycle that was around 40% lighter than e-bike industry benchmarks, improving user appeal, experience, performance and range.

High Power Batteries – The Need for Improved Cooling Solutions

The project aim was to design and develop a cooling system and build it into a battery module to allow the high power 18650 cells used to discharge at their maximum rate from full charge to minimum SOC without overheating.

The completed module was independently tested at Warwick University with the test results surpassing the CFD predictions. The unique cooling system prevented any part of the module from exceeding the cell manufacturer’s temperature limits.

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Electrification of an Autonomous Off-Highway Vehicle

The project aim was to develop an electric, fully driverless tractor for the orchard and polytunnel farming sectors with the inherent high torque and reliability characteristics of an electric motor particularly suited to off-highway drivetrain and power-take-off application.

The synergies between tractor electrification and fully driverless functionality means there is no need to specify a large battery pack and a different duty cycle can also be specified with shorter charge/discharge cycles, reducing battery cost. Electrification also enables a different powertrain layout with a separate motor for each wheel and power-take-off, reducing assembly costs and complexity.

The project successfully designed and assembled a 70kWh driverless electric tractor with a 320V battery system.

Aerocool VL - Passive Air Based Battery-Cooling Concept

The project aim was to investigate the technical and commercial feasibility of using an innovative battery cooling concept to provide high performance battery cooling without the added complexity, weight and safety implications of liquid-based cooling systems.

The project has provided both a proof of the original concept along with an enhanced understanding of the technology in a real-world application. This is backed up with actual detailed test results and data on the battery cooling along with the suitability of using air cooling for an EV-battery pack.

Electric Vehicle Thermal Hub

A Thermal Hub concept for Electric Vehicles storing waste heat generated during normal running in PCM Heat Batteries and redistributing it during cold ambient conditions, thereby improving the efficiency of the EV battery and vehicle range considerably (over 16% improvement).

The project has resulted in the development of Dual PCM Heat Batteries and a pump module to transport, store and utilise heat energy around 3 circuits within a Nissan eNV200 van. Initial testing has proven the concept and Climatic chamber testing is scheduled for mid-2019.

Fuel Economy Benefits Enabled by Rapid Engine Warm-Up

The aim of this project was to produce a low cost solution that reduces engine warm up times and improves fuel economy for legislative drive cycles and real world driving. The design of the technology means that it can be retrofitted to any IC engine.

The concept level prototype installed in a NV car demonstrated a clear improvement in oil warm up time. Across a full 30 minute WLTP cycle, no measurable improvement in fuel economy was demonstrated but for a shorter 8 minute cycle, representative of a range extender application, a 1% benefit was measured.

Hybrid Concept Car by RFR

The aim of the first stage project was to deliver the proof of concept for a hybrid road car, where the power units would be split between an IC engine driving the rear wheels and electric motors driving the front.

The RFR team integrated an electric supercharger to help match up the power of the IC engine and the electric motors, the aim of which was to drive the car with both power units working separately as well as together in a basic form.

The RFR team and project partners, Osprey Research and Aeristech, were successful in achieving these goals. The NVN funding has helped bring this project forward and the next step and key goal of the second stage, is to produce the final version of the British made hypercar and to overcome the challenge of ensuring that the integration of the 2 power units are working together correctly and simultaneously.

Hybrid Concept Car by RFRProject Partners

Osprey Research Ltd - http://www.ospreyresearch.co.uk

Aeristec Ltd - https://www.aeristech.co.uk

The aim of the first stage project was the proof of concept for a hybrid road car; the powerunits would be split between an IC engine driving the rear wheels with electric motors drivingthe front.

RFR team integrated an electric supercharger to help match up the power of the IC engines andthe electric motors, the aim of which was driving the car with both power units workingseparately as well as them working together in a basic form.

RFR team successfully managed to achieve our goals and it all worked well with our partners.The Niche Funding helped us bring this project forward and our next step is to produce thefinal version of the British Made Hypercar, the next challenge will now be to make sure theintegration of the 2 power units are working together correctly simultaneously. This is now thegoal of this second stage.

Braided Automotive Composite Springs (BACS)

The project set out the ambitious target to develop and produce a fully functional braided composite spring that can replace stock steel springs in automotive suspension applications. This will give weight savings and better acoustic isolation suitable for volume production.

The outcomes:

• Parametric spring model with geometric design parameters including fibre composition to predict stiffness & strength

• A phased consolidation process to be further developed and tested

• A first prototype composite hollow coil spring, 36% lighter than its steel equivalent

Spring damper unit in Ariel Nomad suspension and packaging studies

Composite sample in bespoke torsion test rig

The braiding and the consolidation process used to manufacture the

composite torsion tube

First prototype hollow composite coil spring

4-point bend test on composite sample

Innovative Zero Emission Niche Sports Car

The project successfully delivered an electric 2 seater sports car prototype electric vehicle for testing and development, prior to series production.

Our goal is to launch into low volume production after completing test & development and manufacturing set-up activities.

Sparrowhawk completed the design and prototype manufacturing of the chassis and mechanical systems

Indra designed and built a 45kWh prototype battery and developed a powertrain controller that controls an OEM inverter and motor, enabling niche vehicle manufacturers to adopt mainstream EV powertrains. They also built a powertrain development mule vehicle

Bespoke Design integrated the outer body shell into the EV chassis

Sparrowhawk

PB Apps - Powderbond™ Applications

Thermoplastic composites combined with aluminium in mixed-material structures, can deliver cost, weight and environmental benefits. The Powderbond™ joining process enables this in structural applications. This project characterises Powderbond™ performance in different joint configurations, in extreme environmental conditions.

Powderbond™ Al–PP/Glass joint performance exceeded the best alternative adhesive solution in all cases. Processing techniques (volume scalable), optimum component, joint and structure designs are now understood and demonstrated in a full structure. This now allows application into vehicle programmes.

Vortex Air Induction System (VANE)

The primary objective of the VANE project was to investigate the effects of a Vortex air intake design on fuel economy and harmful emissions. The patented design incorporated Vortex air flow technology, forming shapes similar to those used in exhaust applications.

Upon project completion, Vortex had proved that the VANE technology reduces fuel consumption at speeds up to 50 mph, while simultaneously lowering harmful emissions. The data obtained allows Vortex and partners to further develop the VANE technology in commercial applications.

External view of the VANE air intake

Pressure distributions 3D streamline

Internal structures of the VANE air intake

Mule vehicle tested for emissions and fuel economy using PEMS

flowdirection flow

direction

AirPOD

The aim of the project was to transfer technology from the autonomous vehicle sector to the aviation and agricultural industries, whilst proving a concept of modular aerial transport system. The consortium aimed to demonstrate the principle of a drone-based cargo delivery system to a given location, and to transfer the cargo to a road vehicle for last mile delivery, all at a scaled level.

An agricultural drone system was developed as the flight platform for the project. A bespoke modular cargo capsule was also designed and manufactured to connect with the UAS. The capsule was then detached via a quick release mechanism before being attached onto an autonomous road rover, which utilised lane following technology for last mile delivery to a specified destination.

DOMINO – Powering last-mile-delivery vehicles

Novel solutions are needed to ensure our last-mile delivery vehicles have zero-emissions, are lightweight and safe. DOMINO has initiated the development of revolutionary structural components that store and deliver energy in a vehicle.

This funded project focussed on the core technology; combining the partners’ expertise in lightweight structural composites (FAR) and safe energy storage technology (ZapGo) to develop enhanced dual-function materials and structures, together with their manufacturing processes.

Hybrid Concept Car by RFRProject Partners

Osprey Research Ltd - http://www.ospreyresearch.co.uk

Aeristec Ltd - https://www.aeristech.co.uk

The aim of the first stage project was the proof of concept for a hybrid road car; the powerunits would be split between an IC engine driving the rear wheels with electric motors drivingthe front.

RFR team integrated an electric supercharger to help match up the power of the IC engines andthe electric motors, the aim of which was driving the car with both power units workingseparately as well as them working together in a basic form.

RFR team successfully managed to achieve our goals and it all worked well with our partners.The Niche Funding helped us bring this project forward and our next step is to produce thefinal version of the British Made Hypercar, the next challenge will now be to make sure theintegration of the 2 power units are working together correctly simultaneously. This is now thegoal of this second stage.

C/O CenexHolywell BuildingHolywell ParkAshby RoadLoughboroughLeicestershireLE11 3UZ

Tel: 01509 642 500

www.nichevehiclenetwork.co.uk