E-Mobility Engineering 015 l EMotive Scarab off-road truck dossier l In Conversation: Giulio Ornella l Hall effect and magnetic sensors focus l Challenge of batteries for heavy-duty EVs l Alpha Motor Corporation digest l Automated charging insight l HVAC systems focus

consumption, conserve resources and minimise the environmental effects that would result from physical r&d. With the models’ industrialisation, the manufacturing methods will be optimised using what Alpha calls “computerised automotive processes”. The virtual validation will also output tested data that can be used to inform the manufacturing processes. Alpha says these digital tools enable seamless navigation of a vehicle’s complex systems and the successful construction of the entire vehicle before any metal is pressed. One of those systems is the power control electronics. At a systems level, the company says that system will be the same in all its vehicles. However, individual vehicle software settings will create differentiation and platform-specific optimisation. Depending on the vehicle classification by weight, the thermal management (as it pertains to energy density determined by battery capacity) will be designed to support the different models’ driving performance. The thermal management involves monitoring cell voltage, functional safety, battery architecture and battery state determination, among other factors. A battery also needs to be isolated from heat and humidity to sustain its operation. Alpha plans to equip its vehicles with lithium-ion batteries to achieve an average of 402 km from a fully charged battery pack across the vehicle line-up. The vehicles will be fully electric and are planned to be fitted with 75-85 kWh batteries to provide a target energy consumption range of 150-160 Wh/km. The battery packs are planned to be composed of eight to 12 modules depending on cell energy density. The battery module locations are being organised into two categories for Alpha’s platforms, utility and passenger. Battery management Utility vehicles are built to drive at an elevated ride height, whereas passenger vehicles are constructed with a lower centre of gravity. Because the battery is the heaviest component in the vehicle, its location determines the vehicle’s centre of gravity. The battery’s location is determined by factors such as the centre of gravity, weight distribution, interior volume and cargo capacity. The location can also deliver functional advantages in comparison to an IC-engined vehicle. At the moment, Alpha says, the optimal location for battery integration in a fully electric vehicle is between the front and rear axles, as defined by the wheelbase length. The location of the cells within the battery pack is also linked to the spatial requirements for thermal management, which relates to the vehicle’s driving performance targets. Other factors that contribute to the location and packing decisions are overall vehicle footprint and overall wheel diameter. This will also affect the driving experience where vehicles have different ride heights and ground clearances. Optimal battery performance is achieved in temperatures from +15 C to 35 C. Weather conditions above or below that are expected to influence the range and potentially reduce it. The battery warranty is planned to be at least 8 years or 160,934 km. The batteries will be recycled and repurposed for potentially 10 more years of use depending on the functionality for its utility, sport and what it calls “adventure” models. Alpha uses what it calls a “zero base design to cost process” to develop its vehicles. It is used to achieve lean manufacturing of the vehicles, which means simplifying the vehicle architecture and systems to reduce their industrialisation footprint. To optimise vehicle architecture the vehicle regulatory compliance, customer requirements, manufacturing feasibility, driving performance and the servicing and maintenance requirements are taken into consideration. The use of virtual models for developing the vehicle architecture, materials composition and manufacturing methodologies are very important for this. The models also allow for a more efficient method of improving the vehicles. Overall, the objective is cost optimisation, which is derived from detailed analysis and feasibility studies of the standardised vehicles and their powertrain. Alpha says this begins with optimising the vehicle architecture, including the powertrain as well as the rest of the components in the vehicle. Virtual validation The company also has a virtual validation process for the vehicles to streamline their physical assembly. The process focuses on the continuous improvement of the models’ industrialisation to reduce energy The prototype of Alpha’s Wolf electric pick-up now serves as the foundation for its other vehicles Autumn 2022 | E-Mobility Engineering 51 Digest | Alpha Motor Corporation