This sidebar examines some of the latest E-Mobility products and technologies from companies like Schaeffler, Eaton and Dana. Check out the full article in the April issue of Power Transmission Engineering:

https://www.powertransmission.com/issues/0420/vehicle-electrification.pdf

Schaeffler Touts E-Mobility Integration 

In the field of hybrid technology, Schaeffler’s P2 hybrid modules allow OE customers to electrify their existing engine and transmission building blocks by the addition of an electric motor that is integrated with the transmission launch device. Through this integration, the growth of the powerpack is minimized such that changes to floor plans or frame rails are eliminated. This integration allows our OE customers to offer a traditional drivetrain or hybridized drivetrain in a common vehicle architecture.

For the Battery Electric Vehicle side of the business, Schaeffler’s compact transmissions for eAxles give OE customers the opportunity to integrate the differential and reduction gearset into a single compact, coaxial unit while delivering state-of-the-art efficiency. This again reduces the space claim of the eAxle so that passenger usable space or battery volume can be increased.

“Both hybrids and battery electric vehicles, the need for an electric motor is clear. Schaeffler’s in-house design of eMotors allows for the integration with the mechanical sub-systems listed above,” said Chris Shamie, vice president, hybrid, eAxles and PMO at Schaeffler Group USA. “By integrating the eMotor and the mechanical portion of the hybrid module, cost and space claims are saved. From the stamped laminations to the insertion and winding of copper, Schaeffler is extending its reputation for vertical integration to eMotor manufacturing which will offer OE customers a turn-key solution.”

Schaeffler’s P2 hybrid modules enable the 2020 Ford Explorer, Lincoln Aviator, and Ford Police Interceptor to be hybridized. In those applications, Ford’s strategy was “No compromises,” meaning that the hybrid versions of these vehicles must perform as good or better than the versions with traditional powertrains.

“For the US market, that meant that the vehicles needed good off-the-line launch feel, and they needed to be able to tow. To deliver those drive characteristics, a torque converter was required, and to fit in the allowable space with a torque converter, an integrated solution was needed,” Shamie said.

Schaeffler’s compact eAxle transmissions are used to drive the 2020 Audi E-Tron and the 2020 Porsche Taycan- two of the hottest BEVs on the market. The architecture chosen for these transmissions yielded great efficiency which increased range over the normal eAxle design paradigms. Learn more at www.schaeffler.us.

Eaton Offers Circuit Protection and Full Transmission Portfolio

Some of the more recent technology debuts includes Breaktor circuit protection, a solution for EVs that combines the function of fuses, pyro switches and contactors into a single coordinated device. As electric vehicle power levels increase, Breaktor solves the ever-increasing coordination challenge between fuses and contactors, and offers extremely fast, safe and reliable protection for high-power battery and inverter systems.

"Our new family of inverters are designed especially for passenger cars with enhanced power density to take up less space in the EV system, while delivering the power required for the vehicle. The inverters’ superior efficiency even contributes to extending range for the EV," said Brian McKay, Ph.D., global head of engineering, E-Mobility at Eaton.

For electric commercial vehicles, Eaton offers a full portfolio of transmissions including a new purpose-built heavy duty 4-speed transmission. Transmissions are beneficial for electric CVs because they allow for better acceleration and gradeability for heavier applications.

"We also are producing FLEX power distribution units, which safely distribute power within the EV system while allowing for modularity for a variety of CV needs," said McKay. (eaton.com)

Dana Offers Diverse E-Mobility Portfolio 

In the light-vehicle market, Dana offers its Spicer Electrified eS4500i e-Drive Unit, which combines a motor, inverter, gearbox, and thermal management in a complete e-Drive system. The company has also started working with Valeo to offer 48-volt electric vehicle systems for low speed and e-AWD applications.

For commercial vehicles, Dana recently introduced the Spicer Electrified eS9000r e-Axle for Class 4 and 5 commercial fleet applications. Dana is the first to market in North America with this e-Axle classification, which is designed for medium-duty truck and bus applications. It is based on the proven and widely specified Spicer S110, S111, and S130 rear drive axle platforms, and it is engineered as a fully integrated e-Axle, including a gearbox and motor.

"We’ve also demonstrated the value of our acquisition of electrification systems specialist Nordresa by integrating the Spicer Electrified eS9000r e-Axle on the Isuzu N-Series chassis for commercial fleet applications," said Christophe Dominiak, senior vice president and chief technology officer at Dana Incorporated.

Also, Dana has designed a direct-drive e-Powertrain system that includes a Spicer Electrified e-Propulsion system and a standard Dana drive axle and driveshaft. The company is  also suppling an e-Power system that generates, stores, and manages the energy for the vehicle and consists of electrified auxiliary systems, an on-board charger, and two battery packs. Dana-developed software and controls enable the diagnostics and telemetry of the complete system.

In the off-highway segment, Dana now supplies Spicer Electrified e-Axles for telehandlers with load capacities up to 3,000 kg (6,600 lbs.) that leverage Dana's industry-leading lineup of motors, inverters, and controls to provide electrified propulsion within established vehicle architectures.

"Additionally, Dana has developed the Spicer Electrified e-Gearbox for telehandlers. It features a compact design that manages high input speeds, provides superior power density, improves mechanical efficiency, and offers a precision-engineered interface for connecting high-performance motors," Dominiak said.  (dana.com)