The 2Zero project EM-TECH has released a new technical publication, Deliverable D6.1 – “Smart e-corner and Smart e-axle assembly”, presenting the integration and distributed real-time testing of two advanced electric powertrain components designed for next-generation zero-emission mobility.

The report describes the experimental integration and validation of the smart e-corner and smart e-axle systems, focusing on the evaluation of electrical and mechanical performance, thermal behaviour, and Noise, Vibration and Harshness (NVH) characteristics. These tests were conducted through a distributed experimental setup combining physical hardware, advanced control platforms and real-time simulation.

Within the project framework, the In-Wheel Motor (IWM) provided by ELA was integrated into the smart e-corner platform at TUIL, while the baseline On-board Axial Flux Motor (AFM) was installed on a dedicated powertrain test rig at USR as part of the smart e-axle system. The AFM configuration also included an inverter from I&M and a virtual gear transmission developed by AVL.

The testing environment was based on a distributed X-in-the-Loop (XiL) architecture that enabled real-time co-simulation between the two laboratories. At TUIL, a dSpace Scalexio rapid prototyping system operated a virtual vehicle model, while USR hosted the e-axle hardware test bench. The two sites were synchronized through a secure VPN connection, allowing coordinated signal exchange and remote hardware testing.

Both test configurations were equipped with comprehensive instrumentation, including voltage, current, torque, temperature and vibration sensors, to capture detailed data on drivetrain behaviour under realistic operating conditions.

Overall, the work demonstrates the effectiveness of distributed XiL methodologies for validating advanced electric drivetrain architectures. The results support more flexible, scalable development processes and contribute to the design of integrated electric powertrains for future mobility platforms.

The full deliverable is available by clicking the following link.