The transition to sustainable mobility is all about efficiency. Key demands include frugal energy consumption for electric drive systems, and faster development processes. From a vast range of possible architectures and technical alternatives, designers must develop highly individual concepts – then fit them into ultra-slim drive units.
CTI SYMPOSIUM GERMANY 2024: An inspiring ideas pool, and a dependable guide
In fourteen Deep Dive sessions with over 80 specialist presentations, all the latest technical developments are on the agenda in Berlin. Browse our program and discover all the relevant topics and current trends for your specific field – plus a wealth of surprising insights and groundbreaking solutions.
Highly integrated EDUs
In the rapidly evolving EV industry, efficiency, cost reduction, and system simplification are paramount. hofer powertrain’s new xONEsolutions set a new standard with innovative eDrive systems that integrate key components into a compact unit, reducing materials and costs by up to 25% and achieving up to 97% efficiency. The xONEdrive and xONEbattery combine vital functions like onboard charging, DC-DC conversion, and thermal management into scalable solutions, supporting voltages from 400 V to 1250 V. These advancements offer a plug-and-play approach for OEMs, enhancing flexibility and paving the way for the future of e-mobility.
In his analysis, Dr Håkan Sandquist (InfiMotion Technology Europe) is equally upbeat on the benefits of integrating additional functions such as DC/DC conversion, on-board charging and battery management system (BMS) into the traction inverter. As he will explain in Berlin, the speaker sees it as a “decisive step on the road to more efficient, more compact and more cost-effective electric drive systems in next-generation vehicles”. Dr Sandquist will underscore how integration permits seamless communication and the coordination of different subsystems, both of which boost overall system performance. He will also share up-to-the-minute information, and present an innovative X-in-1 EDU developed by InfiMotion whose SOP recently began in China.
Always a gripping topic : Wheel hub drives and AWDs
Sophisticated all-wheel drives with two powerful electric motors and ultra-compact wheel hub motors are one of the most fascinating e-drive applications – and an endless source of interesting challenges for developers.
How do different e-motor architectures and axle decoupling options affect the energy efficiency and system costs of 4WD BEVs? To answer that question, Jeff Waterstredt (BorgWarner) will be presenting a simulation-based study that compares the performance of permanent magnet (PM) and induction (IM) motors on front and rear axles, with and without disconnect clutches, under different driving cycles and power-to-weight ratios. The study also examines the impact of the disconnect clutches’ positioning on transmission drag losses and motor efficiency. As the speaker will show, the best configuration for optimal energy efficiency and system cost reduction across all operating conditions is a combination of IM and PM motors with disconnect clutches on both axles. This finding challenges the conventional view that induction motors for secondary axles eliminate the need for, or benefits of, axle decoupling.
Are there new opportunities for wheel hub drives, and could they even become cost-effective for the mass market? In his analysis, Patrick Starke (IAV) will first point out the classic advantages in terms of package and driving cycle consumption, then show how factors such as axial flow machines and radial flow machines with double rotors can improve affordability by increasing power and torque densities. The speaker will present a study that offers in-depth answers for a passenger car in the C segment. He will compare various wheel hub drive trains with a conventional central drive, and analyse the combination of inverter, electric motor and battery with regard to costs, energy consumption and package. Other points will include the benefits of improved vehicle aerodynamics, and the use of more cost-effective battery storage in various future scenarios.
Tough challenges : Three highly efficient solutions
Cost-sensitive customers, rising material prices, falling subsidies … electromobility is facing serious challenges. To succeed, modern drives must be developed quickly, then made market-ready as soon as possible. The three projects described below show how this can be achieved.
Slim e-axles for affordable vehicles
Matthieu Rihn (Marelli EPT Strasbourg) is convinced that the demand for compact, affordable vehicles will grow. In his talk, he cites trends in markets such as India and quotes Luca de Meo (CEO of Renault), who proposed targeted promotion measures for European small cars in his “Letter to Europe”. For the e-axles these vehicles require, weight and cost reductions are top priorities, and their system power should not exceed 100kW. As Matthieu Rihn will explain, developing slim e-axles calls for a new approach at system level. The e-motors are small, with high RPM; inverters are integrated into the main housing, and preferably run at 400 V; cooling and lubricant circuits are optimized to the max. The aim is to not only use existing, proven technology, but to integrate it intelligently as well. When it comes to slim e-axles, less is definitely more.
EDU system with > 94% average cycle efficiency
AVL has been looking at ways of increasing range and charging speeds by improving the overall efficiency of BEVs. As Wilhelm Vallant (AVL) will show in Berlin, the result is a highly efficient EDU that consumes just 10 kWh/100km and has an average WLTC cycle efficiency of >94% at the charging point. The speaker will first describe the framework conditions AVL set in order to determine the most suitable EDU system for a B/C segment vehicle with maximum energy efficiency. The methodology for the concept evaluation and initial dimensioning of the electric motor, transmission and inverter components was structured with the aid of AI-supported DOE. Target achievement was verified by means of hardware bench tests. To achieve the highest average final efficiency in both WLTC and CLTC, various system designs were also compared and their differences mapped. The study was based on a customer project that ran in parallel to the company’s internal R&D activities.
Valeo Gen5 eDrive : A platform solution with extreme power density
Karsten Kühlkamp (Valeo eAutomotive) will be presenting a new electric axle platform called Valeo Gen5 Drive. With a wealth of technical options (400V or 800V nominal voltage, oil and water-cooled motors, parking locks and disconnectors, scalable power modules), this new drive is designed to meet market requirements in full. The Valeo Gen5 eDrive is an optimiszed, scalable solution for power classes from 100 kW to 250 kW, in a flexible vertical or horizontal architecture with common interfaces, components and subsystems. As the speaker will explain, this is the key to continuous optimiszation processes in terms of performance and efficiency. In his presentation, Karsten Kühlkamp will focus on the platform solution for the medium (150 kW) power segment. His simulation and test results will show how the prototype based on the platform solution combines outstanding power density with high WLTC driving cycle efficiency. In a more detailed analysis, he will identify different design features that help to reduce losses, and discuss possible measures for taking efficiency higher still.
Toyota’s Accessible People Mover: Mobility for Olympic participants
At the 2024 Olympics and Paralympics in Paris, Toyota provided an entire fleet of Accessible People Movers (APMs) for people with reduced mobility. Toyota Motor Europe was responsible for all aspects of vehicle development, from initial design concepts to vehicle production at Toyota Caetano. Key project partners were FEV Europe GmbH, and the battery supplier Forsee Power. In a joint presentation, Thomas Haine (Toyota Motor Europe), Frederik Baudrier (Forsee Power) and Nabal Pandey (FEV Europe) will provide insights into how the APM electric drive system was developed.
In their three-part talk, they will pay special attention to the 48V traction battery. Part One will describe how the development work was frontloaded by creating a virtual vehicle model, then running simulations to select standard drivetrain components. Part Two will describe how the selected components were integrated into the drivetrain system. Part Three will cover the validation process for both the design, and the effectiveness of countermeasures derived from the design review. Overall, the presentation will offer deep insights into the development of 48-volt electric drivetrain systems for low volume production. By combining cost-effective design solutions with flexible control logic, Toyota and its partners were able to meet unique product requirements.
CTI Symposium Berlin: Book now to end 2024 on a high note!
Be right there when decision-makers and experts share cutting-edge insights into the topics that are moving our industry on December 3rd and 4th, 2024 in Berlin. Select your own personal highlights from a two-day program packed with Deep Dive sessions, lectures and discussions by decision-makers and experts in the plenary session and at CTI EXPO. Once again, the undisputed glamour highlight will be the Networking Night, held in the Arminius Market Hall. This year’s program also features two new highlights: The special START UP AREA is a showcase for potential stars of tomorrow, while our WOMEN @ CTI SPECIAL PROGRAM is reserved exclusively for female participants.
Welcome to Berlin!
