Earlier this week, the UK project set up to create ground-breaking developments in electric motorcycle engineering and innovative integrated technology design was revealed in completed prototype form.  Known as Project Triumph TE-1, the collaboration of Triumph Motorcycles, Williams Advanced Engineering (WAE), Integral Powertrain Ltd., and WMG (Warwick Manufacturing Group) at the University of Warwick was funded by the Office for Zero Emission Vehicles through Innovate UK.

The objective of the project, which was kicked off in May 2019, is on developing electric motorcycle capability and providing input into Triumph’s future electric motorcycle offering. At a higher level, it is meant to drive innovation, capability, new intellectual property, and enhance the credibility and profile of British industry and design. Key project achievements during this phase include test results that exceed current benchmarks and targets set by the UK Automotive Council for 2025, providing a platform with potential for future development in electric motorcycle performance.

The Triumph TE-1 team began Phase 3 by successfully building an initial mule bike, which incorporated the battery, inverter, motor, and chassis into one machine for the first time. Using this platform, the project partners worked collaboratively to optimize software integration across the complex systems, involving hundreds of hours of detailed testing to ensure the functionality of all the features and software aspects behave accurately and intuitively as a customer would expect.

This was validated in real-life simulation work carried out at WMG involving detailed powertrain rig testing and simulations to assess safety-critical items relating to motor function and vehicle control. Durability testing on the primary transmission was also conducted to ensure a full understanding of the fundamental differences in electric motor load application for vehicle use cases, efficiency, and consequences to gear life.

Alongside this work, the Triumph-led design of the bespoke chassis focused on delivering the Phase 2 styling intent as closely as possible.

“It has been truly exciting to see the progress made during Phase 3 of Project Triumph TE‑1, with the final prototype motorcycle now going into real-life testing,” said Nick Bloor, Triumph CEO. “Everyone involved at Triumph is proud to have been part of this innovative British collaboration. Personally, I am thrilled with the results we have already achieved with our partners, and the exciting preview of the potential electric future to come.”

 

WAE battery system

WAE was responsible for the bike’s lightweight battery system. Following completion of Phase 2 of the program in March 2021, which delivered a fully bench tested battery, the company says its work on Phase 3 involved critical gateways for the project. In addition to supporting a number of hardware and software solutions, specifically integrating Triumph’s motorcycle control software to work with WAE’s controller and battery management system, the team has enhanced the integration of the mechanical and electrical solutions, optimizing battery layout to balance mass and positioning within the chassis.

“By working with the team at Triumph, we have continued to push the boundaries of battery technology, keeping the rider in mind at all times,” said Dyrr Ardash, Head of Strategic Partnerships, Williams Advanced Engineering. “Because we have designed the battery from the ground-up, design has not been compromised and we have been able to maximize the potential of cutting-edge technology, offering both performance and all-important range.”

WAE says it employed a holistic approach to development intended to allow riders to use more electric power for longer, providing access to performance regardless of battery charge and rapid charging times. The battery pack incorporates dedicated cell packaging for an optimum center-of-gravity, vehicle control unit, DC/DC converter, integrated cooling, charge port, and styled carbon covers.

The new WAE-developed powertrain is said to set new standards for electric bike performance with class-leading power, efficiency, charging time, and range. The battery has 170 kW peak and 90 kW continuous power, with a capacity of 15 kWh. This enables the motorbike to deliver a 130 kW peak and 80 kW continuous power.

A claimed class-leading cooling system combined with the optimum balance of power and energy means TE-1 can give a rider more electric power for longer and deliver that performance regardless of battery charge. The 360-V system enables a 0% to 80% fast-charging time of under 20 min combined with a claimed market-leading target range.

 

Integral motor and inverter

Integral e-Drive developed an integrated motor and inverter powertrain as part of the project. The company combined a custom, high-power-density electric motor with a new, ultra-low-loss silicon carbide power stage—with no phase cables, busbars, or separate cooling circuits.

Initial performance test results are said to far exceed the current benchmarks and industry targets. For the TE-1 application, the motor achieves peak and continuous power densities of 13 kW/kg and 9 kW/kg, respectively, which is 60% higher than the new APC technology roadmap targets for 2025.

“All of this has been achieved using materials and processes compatible with volume automotive production and importantly using a length scalable motor platform,” said Andrew Cross, Chief Technical Officer, Integral Powertrain Ltd. “The inverter concept, which is also scalable by tuning the number of silicon-carbide power stages for different diameter motors, has really delivered on performance. The TE-1 unit is capable of more than 500 kW. This gives us the opportunity to optimize this platform for production.”

 

Triumph taking on Stage 4

The completed demonstrator marks the official end of the collaboration stage of the TE-1 project. The next Triumph-led stage of the project is the live testing program, which will integrate all the latest and final innovations from the project partner workstreams.

“During Phase 3, we have focused on building the physical foundation of Triumph’s first electric prototype motorcycle,” said Steve Sargent, Triumph’s Chief Product Officer. “I am pleased with the outcome of Triumph and the TE-1 partners’ efforts in creating a demonstrator bike that is not only visually so desirable with clear Triumph DNA, but also packaged with an exhilarating and thrilling brand-new electric powertrain that has such potential for the future.”

Over the next six months, an extensive testing program will be conducted at Triumph’s facilities, including rolling road and track testing, designed to provide direction into the final setup and calibration of the prototype demonstrator.

“I look forward to continuing the development of this demonstrator vehicle through Phase 4 and using our knowledge and capabilities to bring all of the partners’ cutting-edge technology together into a final result, which will guide Triumph’s electric strategy for the future,” added Sargent. “Our experience tells us that, at this stage of a project, there is no substitute to genuinely riding a bike when developing driveability, handling, and character. We have ambitious targets focused on delivering a riding experience that is new and exciting, but ultimately intuitive and familiar.”

At the completion of the live testing phase, estimated to be in the summer, the prototype demonstrator will be updated with its final body panels in preparation for track demonstration. At that time, final specifications and testing outcomes will be published, as well as insights and key facts on how the TE-1 delivers on the project targets including final battery and range performance.