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DRIVEMODE - integrated drivetrain modules

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Context

Transport is the fastest growing source of fossil-fuel CO2 emissions, responsible for the emission of 27% of total greenhouse gas emissions in the EU, of which 72% derive from road transport.

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As defined in the White Paper for transport from 2011, the European Union aims to reduce CO2 emissions from transport by 60% compared to 1990 level by 2050.

In order to do so, the EU has launched the Green Vehicle Initiative, which aims to reach the following targets:
  • Create more energy efficient vehicles using alternative powertrains, strengthening the future competitiveness of the automotive industry.
  • Match the transport needs within the EU with highly efficient and more flexible mobility products & services.
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Challenges & Solutions

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The reduced dimension and the lighter weight of the motors designed by DRIVEMODE offer energy savings for consumers and allow vehicles to travel further on a single charge.

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Increasingly, the industry is moving away from silicon to the use of silicon carbide inverters (SiCs), which have a number of significant advantages when twinned with high-voltage systems. SiCs are ideal in DRIVEMODE's modular approach because they allow a reduction in the size of all the crucial components.

 “If you go to higher battery voltage and require less current, you also need smaller cables and smaller cables means less cost, less weight in the vehicle. It is also easier to assemble [the modules] in the vehicle.” affirms Roland Bittner, senior engineer at Semikron Elektronik, a partner of DRIVEMODE.















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Higher-voltage systems such as DRIVEMODE's can cut charging times by up to 75% in vehicles using high-speed chargers.
In the real world this means that a car such as the Porsche Taycan, currently the only commercial 800-volt vehicle on the market, can be charged to 80% of its battery capacity in just over 20 minutes.
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Part of the reason for the high pricing is a lack of uniformity in production. But there are other big hurdles that impact the cost of BEVs, and they include the cost of batteries and high raw material costs.

With DRIVEMODE we have a very integrated unit. That way it makes [everything including] the assembly process, the sourcing, the storing and the assembly, to putting it in the vehicle, very optimal, so you have a reduced production cost,” explains Deepak Singh, an engineer from National Electric Vehicle Sweden (NEVS), one of the project’s partners.

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According to Deepak Singh, an engineer from National Electric Vehicle Sweden (NEVS), there are three main issues facing mass production of electric vehicles
  1. Financial: higher production cost, translated to higher price for EVs.
  2. Manufacturing: the bottleneck due to the supply chain (battery cell, power electronics suppliers).
  3. Design and development.
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Innovation & Results

To solve the above-mentioned issues, the EU-funded project DRIVEMODE has been working on developing the next generation electric drives in seeking to develop a highly efficient and compact modular electric drivetrain consisting of
  • power electronics
  • a gearbox
  • the motor
These modules are designed to be scalable according to the power requirements of different vehicle segments. That means that one of the modules could be used to drive a small city car, while a sports-car might require four modules.
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A mid-sized C-segment car was selected for concept demonstration in DRIVEMODE.

Key data:
• Vehicle weight – 1734 kg
• Top speed – 176 km/h
• Acceleration 0 - 100km – 9.8sec
• Wheel Torque – 3100 Nm
• WLTC efficiency – 64%
• WLTC energy/km –156 Wh/km
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Benefits

Compared to current battery electric vehicles, DRIVEMODE's Integrated Modular Distributed Drivetrain allows for
  • A reduced electric vehicles' cost.
  • An increased battery duration and therefore the possibility to travel longer distances with a single charge.
  • A much shorter charging time.
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Learn more

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