LELR and MESR Rovers for the canadian space agency
CTA was mandated for the design and construction of the frame and propulsion systems of two types of light rovers. A 5.6 M$ contract was awarded to CTA by MacDonald Dettwiler and Associates (MDA) in the context of the surface exploration Mobility program of the Canadian Space Agency. Terrestrial prototypes of these rovers were designed and fabricated based on light alloys and aerospace materials. The custom designed electric propulsion system is powered by CTA batteries that are recharged by on-board solar panels. The rovers were designed to be compatible with hydrogen fuel cell power supply.
econcept Can-Am Spyder for BRP
- Full electric plug-in Roadster.
- 20 kW continuous, 35 kW peak electric motor.
- 96V lithium-ion batteries.
- Regenerative braking.
- On-board Battery Management System (BMS).
- 150 km/h top speed.
- Up to 170 km autonomy.
- eConcept Can-Am Spyder
Electrically-Powered Optionally-Piloted Powered-Lift Aircraft (EOPA) for United Therapeutics
Part of a consortium of specialists, CTA undertook the feasibility study and electric propulsion dimensioning for an electric vertical takeoff and landing aircraft. The tiltwing design has 8 electric propellers on the wing, assisted by four on the tail. The two surfaces tilt from vertical at takeoff and landing to horizontal in high speed cruise operation. The aircraft is designed to assume rapid transportation of human organs.
Batteries and energy management systems
- Design and prototyping of stationary and on-board battery systems.
- Up to 190 W-h/kg power density.
- Proprietary thermal protection system using phase change materials.
- Thermal performance and ageing prediction through simulation.
- Integrated Battery Management System (BMS).
SL-Commander for the Canadian Space Agency
Workbech vehicle for validation of technology to be used on lunar rovers. Based on BRP’s side-by-side Commander off-road vehicle, this full electric propulsion platform was designed by CTA, including a low noise driveline. The vehicle can reach 40 km/h, has an autonomy of over 100 km and can be manually operated or remotely controlled.
The vehicle developped for MacDonald, Dettwiler and Associates (MDA) is a technology validation platform for lunar rovers. It is equiped with adaptable mounting plates allowing for various equipment to be tested. With a fully electric propulsion system using lithium-ion batteries and solar panels for recharging, it allows for 1 h autonomy at 20 km/h. The vehicle can be manually operated or remotely controled.
controler for Can-Am Spyder SE6 transmission
CTA developed the hydraulic system as well as the control logic for BRP’s flagship SE6 transmission implemented in the company’s Can-Am Roadsters. The system controls clutch engagement and gear shifting in order to provide quick and smooth gear changes, regardless of operating conditions or driver behaviour. The system has also the ability to compensate for component wear throughout the life of the vehicle.
cvt transmission and its controLler
CTA developed for BRP a steel belt automatic Continuously Variable Transmission (CVT), as well as its control functions, tailored to the size and weight of recreational vehicles. This transmission allows the engine to operate at its highest efficiency point, reducing fuel consumption and emissions. The belt pinching forces and shift times are controled using adaptive algorythms that take into account the driver’s requests and road conditions, eliminating torque interruptions during shifts thus increasing rider comfort.
Boat low speed controller
Development and prototyping of a boat positioning system consisting of multi-directional water jets, driver control interface and an intelligent controler to finely control a boat’s position in low speed maneuvers. The system allows safe docking and manoeuvering in a tight marina environment.
Design, prototyping and testing of SHOT starting system
CTA has designed, prototyped and tested the SHOT starting system for BRP, a battery-and-starter-less starting system for two stroke snowmobiles. The patented technology uses a specially designed starter-generator as well as electric energy accumulators to ensure that a sufficient amout of energy is stored to restart a warmed-up engine. The system allows a significant weight reduction, increasing competitivity of BRP vehicles.
Search and rescue personal watercraft
Personal watercrafts are especially well adapted to navigate in waters inaccessible to conventional boats. Their shallow draught and high maneuverability make it the ideal craft for CTA’s Search and Rescue (SAR) vehicle, a highly adapted personal watercraft aimed at rescue operations in rough waters. The rescue personal watercraft won the prestigious Red Dot design award as well as the Award of Excellence for Innovation from the National Search and Rescue Program of Canada.
Oxygen helmet visor and elink connection
Simulation and optimization techniques allowed CTA to test numerically hundreds of heated visor configurations and predict their defrosting performance without reaching high surface temperatures that would otherwise damage the visor. In addition, CTA collaborated to the development of the eLink helmet connector that powers the new visor through a novel magnetic connection. The final design led to an innovative new helmet having the largest heated visor on the market.
Class 8 aerodynamic drag reduction
Objective : reduce the electrical consumption and mirror soiling effects for a full electric class 8 truck.
Results : airflow simulations using Computational Fluid Dynamics (CFD) predicting aerodynamic drag and pressure distribution around the vehicle, allowed the Compagnie Électrique Lion to test numerically numerous aerodynamic details and reduce drag of their novel class 8 truck. Visualization of the flow lines helped guide the engineering team with technical decisions to reduce soiling effects.
wind and turbulence protection to the riders
Objective : maximize rider comfort.
Results : using Computational Fluid Dynamics (CFD) to predict airflow around passengers, heat rejection from the engine compartment, size of the protection “bubble” and level of turbulence at the helmet, BRP’s engineering team was able to take decisions to manage the airflow in and around the vehicle. The result is greater rider comfort through reduction of the amount of hot air channeled to the riders, proper sizing of the protection “bubble” and turbulence reduction at the helmet level, even before the first prototype build.
Engine compartment temperature distribution prediction
Objective : predict underhood air temperatures and component temperatures in order to increase vehicle reliability.
Results : using advanced CFD techniques combining the effect of convection, conduction and radiation, CTA conducted aerothermal analysis of vehicles under development to predict underhood air and component temperatures . The analysis allowed the BRP engineering team to understand the internal flow structure under various operating conditions and select materials according to the predicted local temperatures. CFD helped taking early decisions to reduce internal temperatures, increase rider comfort and increase vehicle reliability before even producing the first prototype.
Will we meet the regulation requirements?
Objective : predict if a novel SSV frame will meet the ROHVA energy absorbtion standard.
Results : using non-linear Finite Element Analysis (FEA) CTA was able to predict the ability of a novel side-by-side vehicle frame to pass the stringent ROHVA certification testing for energy absorbtion and frame deformation. FEA has allowed to identify issues and solve them before building the first prototype, reducing the number of prototypes needed for BRP as well as development time and costs.
topologic optimisation of suspension components
Objective : increase vehicle competitivity through mass reduction.
Results : for high performance vehicles going over land, water, air and space, component mass is under high scrutiny. Using topologic optimization allowed to reduce significantly the mass of suspension components while meeting the strength requirements, thus reducing moving masses and increasing overall vehicle competitivity.
Mechanical resistance and energy absorbtion prediction
Objective : predict if a bumper structure is capable to meet FMVSS standards.
Results : using non-linear Finite Element Analysis (FEA), CTA supported the Remcor engineering team in predicting the behaviour and energy absorbtion of rear underride systems when subjected to the requirements of FMVSS standards. Simulations allowed Remcor to visualize the predicted failure modes and improve the design to ensure the system would meet the requirements while reducing significantly the development cost and time.
Predicting internal suspension forces of a vehicle
Objective : reduce the number of prototypes and development effort.
Results : in order to meet its objective, BRP mandated CTA to develop and test a simulation methodology allowing to predict the forces transmitted from the suspension to the vehicle frame in order to use them in Finite Element Analysis (FEA) of the frame. CTA has developed the use of Multibody Dynamics (MBD) to simulate vehicles undergoing driving events and extracting the forces generated at the suspension connection points. This methodology allows BRP to evaluate frame resistance before even the first prototype is built, thus saving precious development time and cost.
virtual reality (VR)
Immersive driving simulator
CTA has completed a Ski-Doo 850 Turbo snowmobile active driving simulator including the following advanced features:
- Handlebar steering feedback.
- A D-BOX movement platform with 4 degrees of freedom (DOF) and more than 25 degrees of pitch movement, 150 mm of vertical movement and 150 mm of longitudinal movement.
- A virtual digital twin positioned exactly on the physical vehicle thanks to advanced machine learning techniques.
- Two driving modes; a beginner mode and an expert mode with countersteering.
- A simulation of a high mountain environment of 2km wide by 6 km in length, completely accessible with a high fidelity rendering designed with HDRP module of Unity, incorporating snow projection effects and volumetric lighting.
- Capturing the pilot’s movement and weight to influence the vehicle behavior.
- Adding a fan whose speed is proportional to the speed of the vehicle.
- Eliminating nausea with the integration of new mitigation procedures.
- Real-time reproduction of engine sound with Krotos Igniter and simulation of the turbo sound of the 850 E-TEC Turbo engine.