IAV at the 26th Aachen Colloquium Automobile and Engine Technology

Working Towards the Intelligent Powertrain

      Concepts and Technologies for Minimum Emissions and Maximum Efficiency

      IAV is preparing the way for zero-emission driving – including an optimum powertrain and alternative drive systems. For all-electric cars, IAV has developed a modular electric drive unit for various powertrain configurations.

      We will be presenting these solutions at the 26th Aachen Colloquium Automobile and Engine Technology on October 9-11:

      The new generation of electric drive units from IAV makes it possible to create an all-electric car. The modular concept consists of an electric motor and a transmission with one to three speeds. The solution that we have developed provides high torque across a wide speed range, takes up little package space and can be mass-produced cost-effectively. The modular electric drive unit ensures high hill-climbing ability and, at the same time, maximum efficiency. It can also be used flexibly and is suitable for various powertrain configurations, such as battery-powered and fuel cell vehicles. (...) More

      In order to meet all the different development targets (CO2 emissions, performance, ride comfort, weight, costs etc.) for 2025 and 2030, OEMs are looking for the most sustainable scenarios in view of the trade-off between fleet consumption, modular systems and costs. The powertrain plays a pivotal role in this search. Fundamental decisions are hugely important and extremely difficult to rectify at a later stage. The targets, requirements and framework conditions are so complex that it is no longer enough to simply optimize the powertrain components using conventional development methods. This is why we are supporting our customers with IAV powertrain synthesis. (...) More

      CNG-fueled vehicles are real climate protectors. Operating on CNG (compressed natural gas), they emit around twenty percent less CO2 than a comparable gasoline engine vehicle. If the gas comes from renewable sources, a reduction of 80 percent is even possible. Added to this are the lower energy taxes on natural gas, making the vehicles attractive for their users from an economic point of view as well. (...) More

      Modular electric drive concept

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      IAV presents the new version of its modular electric drive concept. Combining e-motor and transmission, it provides up to three speeds and, because of its modular concept, can be made to suit various vehicle platforms and demands. The aim is to combine a high level of ride comfort, efficiency and compact package at competitive cost.

      Long-term, electric drive systems will play a key part in mobility because they permit zero-emission mobility and are not reliant on fossil energy. Besides the environmental aspect, manufacturers also need to consider their customers’ demands on ride comfort.

      At the same time, consumers expect top efficiency to give them maximum traveling range, good hill-climbing performance, high vehicle speed and good acceleration on one battery charge.
      Many of today’s electric drives use a combination of an e-motor and transmission with fixed gear ratio.

      Although solutions of this type are relatively simple in terms of structure, they cannot meet all of the demands made on them at the same time. For instance, high hill-climbing performance and maximum efficiency demand very different transmission ratios. It is for this reason that IAV has chosen a modular concept based on an e-motor and a transmission with one to three speeds.

      “As a result, we can match the electric drive unit to different vehicle platforms and demands”, explains Mathias Krause, head of the Cylinder Head/Crankcase department in IAV’s Powertrain System Development division. “Our solution delivers a high level of torque across a wide vehicle speed range.”

      Suitable for various powertrain configurations

      IAV’s solution is also flexible in terms of use – as the main drive for battery-powered electric vehicles, for fuel cell vehicles or as a component of plug-in hybrids. Its power output is sufficient for vehicles from classes A (subcompact car), B (compact car), C (standard size) and D (upper standard size). It represents a further development of a solution IAV presented back in 2010.
      In the modular electric drive unit, an e-motor developed by IAV delivers a continuous power output of 50 kilowatts and maximum power of 80 kilowatts. It generates constant torque of 150 newton meters which can be increased to 300 newton meters for short periods of time. It was designed using IAV’s e-motor synthesis tool which finds the optimum solution for the given application from an almost unlimited number of potential variants.

      Providing a maximum of three speeds, the planetary transmission is installed at the side of the e-motor and is capable of generating output torque levels of up to 3,000 newton meters. At the same time, this makes it possible to limit the motor’s maximum speed to 8,000 revolutions per minute. The differential is accommodated in the e-motor, making optimum use of limited package.

      Traveling range increased by up to ten percent

      “Our modular electric drive unit meets the demands on torque with more speeds than comparable solutions”, says Jens Liebold, Technical Consultant for Electromechanical Drive Systems at IAV. “Instead of a multiple-speed transmission, these use a larger motor with means they need more package and encounter problems because of the higher motor speeds involved, such as with NVH.” Solutions with a fixed transmission ratio also come with efficiency drawbacks, IAV’s solution increases traveling range by five to ten percent.

      Developing the casing also presented a particular challenge. Compact design, a high level of functional integration and temperature management have been combined to provide additional benefits. With IAV’s solution, for example, the power electronics are accommodated in the casing to reduce costs from copper wiring, ensure good EMC shielding as well as include the power electronics in the electric motor’s cooling circuit. “In our case, we use the stator’s circuit to control the temperature of the power electronics because we can bring it into contact with a large area of the casing’s cooled sections”, Krause says. “The transmission lubrication system, in turn, also cools the e-machine’s rotor.”

      Besides this, the project also placed exacting demands on the casing’s structural stiffness. “Otherwise there is a risk of getting problems with acoustic behavior”, Liebold explains. “So the casing had to be as stiff as possible to avoid vibration but also to absorb forces and transfer them to the vehicle.” In developing the casing, IAV’s experts cooperated closely with Nemak, a globally operating aluminum casting specialist. This has resulted in a casing that combines compact size, high stiffness, a high level of functional integration and competitive costs.

      Drive unit

      • Suitable for vehicle classes A to D
      • Hill-climbing ability: maximum of 30 percent
      • Top speed: 160 km/h (continuous) / 185 km/h (maximum)
      • Acceleration 0 – 60 km/h in 4 seconds, 0 – 100 km/h in 10 seconds

      E-motor

      • Power output: 50 kW (continuous) / 80 kW (maximum)
      • Torque: 150 Nm (continuous) / 300 Nm (maximum)

      Transmission

      • Maximum of three speeds
      • Torque: 3,000 Nm (maximum)
    • Map – IAV at the Aachen Colloquium

      Event venue

      Eurogress Aachen
      Monheimsallee 48
      52062 Aachen

      Event times

      Tuesday 10 October
      8.30 am – 6 pm

      Wednesday 11 October
      8.30 am – 4.45 pm

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