SYS2WHEEL · Project

Brand-Independent Electric Drivetrain Kits That Cut Commercial Vehicle Conversion Costs by 20%

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Imagine you want to turn a regular delivery van into an electric one, but every brand needs completely different parts — expensive and slow. SYS2WHEEL built a universal electric drivetrain kit, like a Lego set that fits multiple van brands and sizes. They created two options: motors built right into the wheels, and a compact electric axle, both designed so manufacturers can snap them into different vehicle platforms without redesigning everything. The goal is to make electric delivery vans cheaper and faster to produce at scale.

By the numbers

20%

Targeted cost reduction in mass production

Consortium partners across 8 countries

75%

Industry partner ratio in consortium

Demo deliverables with integration-ready hardware

Industry partners involved

The business problem

What needed solving

Electric commercial vehicles for city logistics are expensive to develop because every vehicle brand and size needs custom-engineered electric drivetrain components. This multiplies engineering costs, slows time-to-market, and keeps prices too high for broad fleet adoption. Manufacturers need universal, plug-and-play electric powertrain systems that work across different vehicle platforms without starting from scratch each time.

The solution

What was built

The project built three key demo systems: an integration-ready e-Axle subsystem, an integration-ready In-Wheel motor subsystem (with a dedicated suspension design), and advanced control software for energy efficiency, drivability, and safety. All were designed as brand-independent, modular components targeting at least 20% cost reduction in mass production.

Audience

Who needs this

Commercial vehicle OEMs converting platforms to electric (e.g., MAN, Iveco, Mercedes-Benz Vans)Last-mile delivery fleet operators seeking affordable electric vans (e.g., DPD, DHL, Amazon Logistics)Tier 1 automotive suppliers expanding into electric commercial vehicle componentsCity governments and transport authorities mandating zero-emission urban logistics zonesElectric vehicle startups building commercial delivery platforms from modular components

Business applications

Who can put this to work

Commercial vehicle manufacturing

enterprise

Target: OEMs and vehicle integrators producing light and medium commercial vehicles (N1/N2 category)

If you are a commercial vehicle manufacturer struggling with high per-model engineering costs for electric variants — this project developed brand-independent in-wheel motor and e-axle systems that fit across multiple vehicle platforms. The modular design targets at least 20% cost reduction in mass production by eliminating redundant components and reducing wiring through time-sensitive networking. With 12 industry partners already involved in integration, the technology was demonstrated on real N1 and N2 vehicles.

Last-mile logistics and fleet operations

any

Target: Urban delivery fleet operators and city logistics companies

If you are a fleet operator looking for affordable electric commercial vehicles for CO2-free city deliveries — this project created drivetrain systems that lower the total cost of ownership for battery electric vans. The space-saving in-wheel and e-axle designs free up room for more cargo, batteries, or driver comfort. Advanced control functions ensure energy efficiency and drivability, meaning your drivers get reliable vehicles that go further on a single charge.

Automotive component supply

mid-size

Target: Tier 1 and Tier 2 automotive suppliers specializing in electric powertrain components

If you are a powertrain component supplier looking to enter or expand in the commercial electric vehicle market — this project produced integration-ready subsystems including improved e-motor windings, advanced rare-earth magnets, and fail-operational safety systems compliant with ISO 26262. The components are designed for scalability across L, N, M1, and M2 vehicle categories, giving you a broader addressable market from a single product line.

Frequently asked

Quick answers

What kind of cost savings can we expect from adopting these drivetrain systems?

The project explicitly targets at least 20% cost reduction in mass production. This comes from eliminating components that become obsolete in the electric architecture and reducing wiring costs through time-sensitive networking. Total cost of ownership is also addressed through improved powertrain efficiency and weight reduction.

Are these systems ready for industrial-scale production?

The project was an Innovation Action that built and demonstrated integration-ready subsystems on N1 and N2 commercial vehicles. Demo deliverables include a complete e-Axle system and a complete In-Wheel system, both ready for vehicle integration. Scaling to mass production would require additional manufacturing partnerships beyond the 16-partner consortium.

What is the IP and licensing situation?

The project involved 16 partners across 8 countries, with 12 industry partners. IP is likely shared among consortium members under the Horizon 2020 grant agreement. Businesses interested in licensing specific components (in-wheel motors, e-axle systems, control software) would need to negotiate with the relevant consortium partner holding that IP.

Which vehicle types can these systems be used for?

The systems were demonstrated on N1 (light commercial, up to 3.5t) and N2 (medium commercial, 3.5-12t) battery electric vehicles. The project also assessed extension potential for the full range of L-category (two/three-wheelers), N-category commercial vehicles, and M1/M2 passenger carriers.

Does this meet automotive safety standards?

Yes. The project specifically addressed automotive quality through advanced fail-operational safety design and ISO 26262 compliance. The advanced control deliverable covers energy efficiency, drivability, safety, and NVH (noise, vibration, harshness) performance.

What was the project timeline and current status?

SYS2WHEEL ran from January 2019 to September 2022 and is now closed. All 11 deliverables were completed, including 3 demo deliverables with physical hardware. The technology is available for commercialization or further development partnerships.

Consortium

Who built it

The SYS2WHEEL consortium is heavily industry-driven, with 12 out of 16 partners (75%) coming from the private sector — a strong signal that this technology was built for real commercial use, not just academic publication. The 8-country spread across AT, DE, ES, IL, IT, SI, TR, and UK covers major European automotive manufacturing hubs. The coordinator, Virtual Vehicle Research GmbH from Austria, is classified as an SME, and 4 SMEs participated overall, balancing large industry capability with agile innovation. With only 1 university and 2 research organizations, the consortium was clearly focused on building and demonstrating hardware rather than exploratory research.

VIRTUAL VEHICLE RESEARCH GMBHCoordinator · AT
IVECO SPAparticipant · IT
ELAPHE POGONSKE TEHNOLOGIJE DOOparticipant · SI
FPT INDUSTRIAL SPAparticipant · IT
AVL COMMERCIAL DRIVELINE & TRACTOR ENGINEERING GMBHthirdparty · AT
IDIADA AUTOMOTIVE TECHNOLOGY SAparticipant · ES
TTTECH AUTO GMBHparticipant · AT
TTTECH COMPUTERTECHNIK AGthirdparty · AT
ALTRA SPAthirdparty · IT
IESTA - INSTITUT FUR INNOVATIVE ENERGIE -STOFFAUSTAUSCHSYSTEMEparticipant · AT
TOFAS TURK OTOMOBIL FABRIKASI ANONIM SIRKETIparticipant · TR
AVL SOFTWARE AND FUNCTIONS GMBHparticipant · DE
UNIVERSITY OF SURREYparticipant · UK

How to reach the team

Virtual Vehicle Research GmbH (Austria) — coordinator. Contact details can be found via their institutional website or the project website.

Order a report on this consortium See VIRTUAL VEHICLE RESEARCH GMBH profile →

Next steps

Talk to the team behind this work.

Want an introduction to the SYS2WHEEL team to discuss licensing or integration of their modular e-drivetrain systems? SciTransfer can organize a direct meeting with the right technical contact.

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