Hybrid and Electric Powertrain

Techrules Ren

Key project requirements

|   Sport PHEV application
|   50C Maximum discharge rate
|   70% Cell to pack weight ratio
|   Pack energy density exceeding 126Wh/kg

Podium Advanced Technologies has designed the innovative four motors and turbine range extender architecture and the battery pack of Ren, the first vehicle from the China-based automotive research and development company Techrules.

The Ren, which made its debut at the 2017 Geneva Motor Show with an innovative design style signed by Fabrizio and Giorgetto Giugiaro, is the world’s first electric production supercar to feature the Techrules-developed Turbine-Recharging Electric Vehicle (TREV) system. The series hybrid powertrain technology delivers high levels of efficiency and performance, and an ultra-low environmental impact.

A variety of configurations will be available to tailor the powertrain to the exact requirements of the customer. The flagship version – with a battery capacity of 25 kWh and with two motors at the front and four at the rear – delivers maximum power of 960kW with a range of 1,170 km from 80 litres of diesel fuel (NEDC).

The drivetrain comprises two, four or six axial flux, liquid-cooled electric motors manufactured by YASA in the UK. 
The rear-wheel-drive two-motor configuration will see a motor driving each rear wheel. A four-motor set-up will drive all four wheels. The highest-power six-motor configuration has two motors for each rear wheel, and one for each front wheel.

Assembly process

Sorting, Testing and Stacking Cylindrical
- Fully automated station
- 100% cells state of health testing (including open circuit voltage, resistance/AC impedance, temperature
- Stations able to handle module up to 1200 mm length
- Different cooling strategies can be handled within this station
- Similar capacity cells can be sorted and included in a module
- Fast and tack-free led lamp curing
- Accurate pressing operation
Sorting, Testing and Stacking Cylindrical
Sorting, Testing and Stacking Prismatic and Pouch
- Fully automated station
- 100% cells state of health testing (including open circuit voltage, resistance/AC impedance, temperature
- Stations can handle different cell dimensions and different thermal extraction strategies
- Accurate pressing operation
Sorting, Testing and Stacking Prismatic and Pouch
Bus Bar Laser Welding
- Cutting edge laser beam technology that guarantees robust joints for several type of busbar connections
- Possibility to weld challenging reflective materials such as CU, Al and dissimiral combination of materials
- Internal development of welding parameters
- Extensive quality control such as weld penetration in process monitoring and resistivity checks
- Stations can handle module up to 1200 mm length and 600 mm width
Bus Bar Laser Welding
Ultrasonic wire bonding
- Fully automatic station
- Wire bonding with the highest axis accuracy
- Continuous real time monitoring of wire condition and process
- Integrated quality control
Ultrasonic wire bonding
Pack assembly stations
- Stations equipped with manual assistors and process dedicated tools to allow assembly teams to work in perfect ergonomic and safe conditions
- Stations equipped with torque monitored tools
- Control tracking system to verify process completion and quality monitoring
- Junction box assembly and quality control
- Controlled sealing application completed after functional test
Pack assembly stations
EOL Testing
- Battery module and pack functional tests
- BMS firmware and software flashing
- Pack cooling system integrity test
EOL Testing

Main features

  • Safety: BMS Design compliant for ISO 26262
  • Scalable slave-master architecture, handles systems
    up to 1.000 V
  • Cell dissipative balancing

Functionalities

  • Real time monitoring cells & components voltage
    and temperatures
  • Advanced algorithms for SOC/SOH estimation
  • Advanced SOP estimation with realtime cell
    thermoelectrical models
  • Electromechanical components feedback monitoring
    and degradation estimation (fuses, contactors)
  • Control and monitoring of the thermal management system
  • Sensing of current, water leak, internal humidity, etc
  • Ground fault monitoring of grounded or ungrounded systems

Services related to BMS

  • Testing and modelling of battery cells
    and systems
  • Experimental characterization of cells
    for accurate state estimation algorithms
    (e.g., SOC, SOE, SOH, SOP)
  • BMS hardware and software development
    for specific applications
  • Prototyping of high-performance
    battery systems
  • Consulting in the field of battery systems

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