Techrules debuts production design for the Ren supercar, with an electric powertrain designed by Podium Engineering

8 March 2017

Geneva, 8 March 2017 – Techrules is debuting the final production design of its first series hybrid supercar at the 2017 Geneva Motor Show. ‘Ren’ is the first production vehicle from the China-based automotive research and development company, and features its proprietary Turbine-Recharging Electric Vehicle (TREV) technology.
 
The Ren features a lightweight chassis that has been designed and constructed to the highest standards by esteemed motorsport specialist, L.M. Gianetti of Turin, who has assigned to Podium Engineering the development of the innovative four motors and turbine range extender architecture and the battery pack.

Ren is the world’s first electric production supercar to feature the Techrules-developed Turbine-Recharging Electric Vehicle (TREV) system, already anticipated at the 2016 Geneva Motor Show. 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 (1,287 hp/1,305 ps) 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. These motors, known as ‘pancake motors’, have a large diameter in relation to their length, making them ideal for use on the Ren as the motors package flat against the inside of the carbon tub, where space is at a premium.

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.

The motors drive each wheel via a reduction gear of 1:3.3 housed in each side plate specially designed for the car. As with the platform, the Ren’s powertrain is also modular, comprising either two, four or six axial flux (biscuit tin) YASA electric motor generators. There are also three available battery capacities: 14 kWh, 25 kWh, and 32 kWh. And customers can choose from either one or two high efficiency 30 kW turbine configuration, or a high power density two-80 kW turbine set-up.

And single YASA motor generates 160 kW / 215 hp (218 ps) and 390 Nm / 288 lb ft. The resulting outputs from the various configurations available are:
– Two motors = 320 kW / 429 hp (435ps) 780 Nm / 575 lb ft
– Four motors = 640 kW / 858 hp (870ps) 1,560 Nm / 1,150 lb ft
– Six motors = 960 kW / 1,287 hp (1,305ps) 2,340 Nm / 1,725 lb ft

The battery pack is designed and manufactured by Podium Engineering specifically for the Ren. It will come in three capacities of 14 kWh, 25 kWh and 32 kWh and can be charged to 80% capacity in under 15 minutes using a DC fast charger. The target lifespan of the battery is 100,000 cycles.

The batteries feature an innovative design and incorporate battery management technologies that enable superior charging efficiency and power balancing between battery cells. Each cell voltage and temperature are independently monitored. Cells are connected via a circuit board instead of wires, for greater durability. The number of cells is 1,344 cell for the 25 kWh version and the pack can deliver 1,200 A, enough to drive six wheel motors at full power.

The battery management system (BMS) is integrated and designed to optimise the performance and life of the battery while ensuring absolute safety. There are three water cooling circuits for the motors, battery and inverter. A heat exchanger (radiator) pack is attached to the front aluminium chassis plate and the cooling circuits are supplied by three electric pumps also mounted on the front plate.

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

Fill the form and upload your CV