1. HEADS (RIP08/3) (Hybrid and Electric Advanced Drive Systems)
Project partners:
Iskra Avtoelektrika d.d.
Hidria Rotomatika d.o.o.
HIDRIA Inštitut za materiale in tehnologijo d.o.o.
Hidria AET d.o.o.
Razvojno tehnološki center za vžigne sisteme in elektroniko d.o.o.

2. About project partners
Iskra Avtoelektrika d.d.
Iskra Avtoelektrika is a global supplier of starter motors and generators for internal combustion engines, electric motors and electrical drive and mechatronic systems for working machinery, means of transport and use of the renewable sources of energy.
Hidria Rotomatika d.o.o., industry of rotary systems
Within the Hidria Corporation, the manufacturing programme of Hidria Rotomatika is located in the industrial pillar with an emphasis on automotive technologies, more precisely steering and drive train systems. The main products are die-cast aluminium components and electrostatic sheet metal and steel components.
HIDRIA Inštitut za materiale in tehnologijo d.o.o. (Hidria Institute for Materials and Technologies)
The Institute represents the main R&D basis for Hidria Rotomatika in the field of automotive technologies.
Hidria AET d.o.o.
Important producer of innovative systems for diesel cold start, fuel heaters and mechatronics parts for diesel engines generation up to EURO 6 and beyond.
Razvojno tehnološki center za vžigne sisteme in elektroniko d.o.o.
Supports mother company Hidria AET with research, development and validation activities.

3. Project description Global chalenges – EU policy:
20% increase of energy efficiency
(Anticipated 10% increase in the use of el. and hybrid drive systems by 2020)
20% renewable energy share by 2020
20% reduction in greenhouse gases (CO2, HC, NOx, Particulate matter-PM)
Expected development direction of these products: introduction of high system voltage, high output power, speed and output torque.
Requirements: high fill factors above 70%, high efficiency above 95% and high specific power, for electrical motors 2kW/kg and for electronic controller over 10kW/liter
Solutions must provide high IP protection and EMC compatibility.

4. Project results Cold start system for diesel engine
System for cold start for diesel engines including glow plug with pressure sensor either with metal or ceramics heater is assembled into diesel engine on the vehicle with corresponding control unit. Pressure sensor in the glow plug enable in-time control of combustion parameters in the cylinder and consequently achieving optimal conditions which lead to lower fuel consumption and lower emissions (NOx).
Electric machines - motor generators
Studies and practical solutions for contactless electrical machines with inserted rare earth permanent magnets, induction generators, motors and alternators for hybrid and electric vehicles with system voltages from 12V up to 500V. The motor generators range from 2 kW to 50 kW of output power. The systems have integrated or separately installed control electronics. The studies also consider the advantages and disadvantages of direct drive inwheel electric motors to drive vehicles . With partners on this project a new vital parts such as stator and rotor laminated stacks were developed and have a defined production process with some real tooling trial run.

5. Project results Electronic controllers BAS (Belt Alternator Starter)
A group of controllers or more precisely motor inverters of different voltage levels (24 VDC ÷ 80 VDC or 600 VDC) for different powers (of a few kW to tens of kW) intended for driving AC induction motors or synchronous IPM (Inserted Permanent Magnets) BLPM (brushless) electric motors. The controllers are designed primarily for the use on hybrid and electric vehicles or vessels and they all support the four-quadrant mode of operation: in a suitable system with an electric motor/generator they allow energy recovery during braking of the vehicle or charging of the batteries while driving with internal combustion engines on vessels.
BAS (Belt Alternator Starter)
The BAS (Belt Alternator Starter) Start–Stop system was developed. Final tests showed that the BAS Start–Stop system is capable of cranking the ICE (Internal Combustion Engine) and a stable operation in generator operation mode. Tests also confirmed that the ECU (Electronic Control Unit) aluminium housing is providing the sufficient cooling for controlers internal components.
Transmission, Cooling System end Electric Energy Storage Studies
Studies of Transmission, Cooling System end Electric Energy Storage provide the basic guidelines for a successful development and the design solutions for the integration of electrical machines and ECU's in electric and hybrid driving systems.

6. Glow plug with integrated pressure sensor
Connector
Power line to the heater and feedback signal line from pressure sensor.
ASIC – Electronic circuit enable processing of signal from pressure sensor and send analog signal to engine control unit
Pressure sensor is integrated into glow plug body and detects pressure forces and transform them into electrical signal which ASICS can read
Metal heater
Hidria AET
Heater function is to glow and consequently causes burning process of the fuel. It could be metal or ceramics type.
Ceramic
heater
Innovative glow plug with piezo type of pressure sensor which significantly differs from existing solutions on the marked. Total system, heater and closed-loop control of combustion are critical factors to reduce fuel consumption and emissions of diesel engine.
Market interest (important producers of diesel engines) for this system is enormous, so ambitious plans of Hidria AET to became one of 3 leading players in this segment is real.

7. BLPM electric motor - ERAD Electric Rear Axel Drive
Iskra Avtoelektrika d.d.
SBU- Driving systems
Electric motor convenient to drive electric and hybrid vehicles is designed to fit in the rear axle together with the differential gearbox :
Electric motor output power of 50kW on 300V to 400V system voltages.
Two working modes: Vehicle Propulsion and Braking
During braking the kinetic energy is recuperated to electric energy and stored to the battery.
Brushless solution without maintenance
Integrated high energy NdFeB permanent magnets for working efficiency over 92%
Reduces the vehicle fuel consumption to an extent of more then 30% and accordingly reduces the environmental pollution .

8. BLPM generator - HVG High Voltage Generator
Iskra Avtoelektrika d.d.
SBU- Driving systems
Electric generator for hybrid vehicles suitable to be mounted on the Internal Combustion Engine:
Works as High Voltage DC generator with 10kW continuous electric power output on 300V to 400V systems.
Intended for belt drive similar to alternators
Regulated output voltage is controlled with correspondent Electronic Control Unit.
Brushless solution without maintenance.
Integrated high energy NdFeB permanent magnets for working efficiency over 92%
Reduces the vehicle fuel consumption and accordingly reduces the environmental pollution .

9. AC electric motor-generator
Iskra Avtoelektrika d.d.
SBU- Driving systems
Electric motor suitable to drive electric vehicles:
Works as a propulsion motor with 15kW output power on 48V DC system voltages.
Motor to be driven with vector control mode provided with correspondent Electronic Control Unit
Brushless solution without maintenance.
Provides zero emission vehicle drive.
Superpiki (Andrej Pečjak) with electric motor from Iskra Avtoelektrika d.d.

10. Product industrialization case – HRB product
Stator lamination
and rotor package
Basic material
ELECTROSTATIC SHEET
METAL
Prototype
Rotor package
HRB
Additional accompanying operations
Product analysis and measurements
Stator lamination quality check
Stator lamination and rotor package
manufacture on a progressive
stamping tool
Stamped-out stator lamination
Preparations, equipment
Additional procedures and
rotor package validation
Material analysis
HIDRIA Rotomatika d.o.o.
HIMIT d.o.o. 10