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Drivetrain solutions Engineering specialists offering complete integration of drive systems are sought after by vehicle manufacturers keen to develop powertrain strategies across their ranges

All major OEMs operate A complete range extended electric platform strategies with vehicle system fitted to the Audi A1 complete drivetrains developed and shared across wide product ranges. But the proliferation of engines, transmissions and hybrid drive systems increases the complexity of the control and integration tasks. Many OEMs are now turning to experienced engineering service providers (ESPs) to support their in-house drivetrain development activities. Notwithstanding the challenges of emissions, performance, energy efficiency, and weight and cost reduction, a new critical paradigm has emerged – the integration of complete drivetrain systems and components. In future the IC engine, gearbox, electric motor and associated systems (such as thermal management) will move closer together to Mahle’s flexible ECU (MFE) lead to new challenges for the become a single, unified controls a wide range of engine in terms of its optimum system that must be engine and vehicle systems design and durability requirements. considered a functional High loads following a cold start can unit. For ESPs, the transmission configurations offers lead to premature wear and thermal expansion of their core many opportunities for the further stresses, while prolonged periods capabilities toward complete integration of hybrid components. of non-use present challenges to propulsion and drive system Full hybrid vehicles use an IC the fuel purge system, component integration is of growing importance. engine, which is not necessarily the corrosion, oil quality and fuel Hybrid vehicles in particular primary power source or method of degradation. The requirements of represent a major challenge in engine and vehicle control units, propulsion. A combination of motors, onboard diagnostics (OBD) may also development and optimization, actuators and sensors. Both the which can be connected to the require periodic engine operation to since there are numerous possible cooling and thermal management engine, transmission or separately check system performance and drivetrain configurations, each with systems have become increasingly connected to the wheels, can act as integrity even if the base operating its own merits and disadvantages. complicated and include radiators, torque-fill, propulsion or generation strategy does not call for it. The Engines can be powered by petrol, heat exchangers, intercoolers and devices. As such, the engine may rapid development of these new diesel, CNG or biofuel. Electric condensers, evaporators, bypass be required to operate continuously, vehicle types, and their differing motors can be mounted separately, valves, multimode pumps, fans or infrequently, depending on the operating strategies, could lead to integrated within the engine or and thermostats. operating strategy of the hybrid revisions to legislation regarding transmission, or mounted in the The conventional choice of system, battery state of charge or OBD and emission testing. This wheels. In certain vehicles, multiple manual or torque converter driver demand. presents a moving target for OEMs, motors are deployed. Batteries also automatic transmissions now The engine may be required to meaning vehicle systems must be vary in shape, size, weight, voltage, includes electromechanical, start and run at high outputs in a reconsidered during production. power rating, chemistry and location dual-clutch, CVT and single- short space of time, become the in the vehicle. speed gearboxes coupled to primary propulsion source and FREE READER INQUIRY SERVICE Electrical and electronic devices conventional differentials and operate similarly to a conventional To learn more about Mahle Pow- used in hybrid architectures include epicyclic or planetary final drive vehicle, or may not be used very ertrain, visit: www.ukipme.com/info/ev INQUIRY NO. XXX inverters, converters, generators, configurations. This expansion in frequently at all. This variation can

214 // July 2015 // Electric & Hybrid Vehicle Technology International