GKN Automotive has developed a new eAxle system that makes it simpler to build plug-in hybrid models on global vehicle platforms.
14 Sep 2015 | 8786 Views | By Autocar Pro News Desk
Driveline technology company GKN Automotive has developed a new eAxle system that makes it simpler to build plug-in hybrid models on global vehicle platforms. This system will be on display at GKN’s stand (H 5.1, B32) at the IAA Motor Show.
The technology is launching on the all-new ...
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Driveline technology company GKN Automotive has developed a new eAxle system that makes it simpler to build plug-in hybrid models on global vehicle platforms. This system will be on display at GKN’s stand (H 5.1, B32) at the IAA Motor Show.
The technology is launching on the all-new Volvo XC90 T8 Twin Engine plug-in hybrid SUV and is the world’s first disconnecting eAxle on a premium SUV. GKN has also worked with Volvo Cars as the development partner on the front-wheel drive and all-wheel drive drivelines of the Volvo XC90, one of the cleanest and most powerful seven-seater SUVs on the market.
Designed to fit in the same space as the Rear Drive Module on the XC90 AWD driveline, the eAxle solution gives Volvo the ultimate flexibility to meet the customer demand mix between all versions of the XC90 driveline. According to GKN Automotive Technology president Peter Moelgg said: “We believe in making hybridisation easier for vehicle manufacturers and more compelling for car buyers. Our technology enables new, axle-split hybrid architectures that make it simpler to integrate a plug-in hybrid powertrain into a global platform and that offer consumers a brilliant mix of electric-drive efficiency and all-wheel drive capability.
“Working with Volvo across all forms of the XC90 driveline enabled us to deliver an electro-mechanical AWD system and hybrid-electric solution that occupies the same packaging dimensions within the vehicle. This gives Volvo the flexibility to ensure production levels can meet the specific customer demand relating to the XC90’s driveline variants.”
The system debuting on the Volvo XC90 delivers new levels of torque in a significantly smaller package. The XC90’s eAxle delivers nominal output torque of 2400Nm in a package that measures 263mm x 310mm x 293mm and weighs just 15kg. The small footprint of this higher output new eAxle saves space, making integration into global vehicle platforms simpler while also enhancing driveability.
By using the electric motor’s output as the transmission input shaft, the result is a smaller, lighter and higher performance electric drivetrain. GKN’s eAxle system incorporates an intelligent disconnect clutch technology that not only provides a more efficient eDrive mode, but also gives the vehicle a powerful all-wheel drive function.
Rainer Link, GKN Driveline managing director of eDrive Systems, added: “While many expected electrification to happen first in small city cars, eAxle systems are enabling larger vehicles and luxury models to electrify much faster. GKN’s pioneering work in eAxle technologies is delivering the torque density that automakers need. Our expertise means that more and more automakers are using GKN as a systems integration partner on hybrid programmes.”
The compact design and low weight is possible due to a semi-integrated-layout where the electric motor and the gearbox share one common housing. GKN’s unique e-Axle is based on a two-stage single-speed coaxial design with an Electronic Disconnect Device (EDD) integrated into the differential.
When e-Axle operation is not required, the electric motor can be decoupled from the drivetrain to minimize losses in combustion engine mode. The system is actuated by a solenoid and includes contactless indication of clutch status.
GKN realised the eAxle’s high internal efficiency of around 95% by using a layshaft gearbox layout. The company is also developing a version that uses a planetary gear set.
GKN, which has pioneered the introduction of eAxle technology in the automotive industry, has been awarded Official Porsche Technology Partner status for its contribution to the plug-in hybrid Porsche 918 Spyder programme. It has also launched the world’s first two-speed eAxle in the plug-in hybrid BMW i8 and the industry’s first eAxle applications with PSA Peugeot Citroen.
GKN Automotive is the world’s leading driveline technology developer, partnering with automakers to make conventional drivetrains more efficient and to make hybrid and electric power more dynamic. GKN Automotive brings together global expertise from GKN’s Driveline and Powder Metallurgy divisions to supply efficient, lightweight and electrified solutions.
GKN will present its innovations between September 17 and September 27 at the IAA in Hall 5.1, Booth B32. The company will hold a press conference at its booth on Wednesday September 16 at 11:30.
GKN executives will be available for interview at IAA Frankfurt during the press days of 15 and 16 September.