Closed loop integration of Electric Drive train and cycle life of Fast Charge LpTO battery systems and Lightweight body structure for E-Buses.

A systems-driven fully integrated design approach for next-generation electric vehicles with electric drive train, fast charge, long cycle life LpTO battery and Lightweight body structure. The Electric bus has been designed with lean manufacturing principles in mind.

As a result, the manufacturing and assembly processes require very little capital investment. This enables the production to be distributed among a number of regional micro-factories, an approach that is readily scalable. The absence of paint booths and bake ovens makes the process very eco-friendly and significantly reduces investment cost.

Addressing system validation of fast charge eBus performances, multi-level monitor systems are required for electric drive train, battery & auxiliary cooling systems and battery cycle life performances

Flexible PLM Software provides this modeling environment, to control and monitor different subsystems to validate drive train, battery and active cooling performances. The electric drive train is design to include best-in-class, integrated functionality for 1D and 3D systems modeling. The design consists of variety of computer-aided and product data management (PDM) software.

Flexible design approaches with knowledge templates is incorporate with best practices for digital simulation. Digitally mock-up of vehicle’s main components and assembly processes provides realistic case studies for digitally optimize configurations and assembly processes.

The race to develop next generation affordable, intelligent, city electric vehicles, we focus on improving electric drive train efficiency, reliability and battery fast charge capabilities. Producers are required to collaborate with electric drive train and software engineers to optimize manufacturing and assembly and charging processes. The key to success will be lightweight material, improved aerodynamics, battery chemistry and minimize total cost of ownership.

Integrated Power train Design Solution

PLM Software provides modeling capability for drive train and manufacturing processes with different subsystems. Overall vehicle performances and designs can be digitally evaluated, modified and enhanced. The electric drive train design is equipped with best-in-class; integrated functionality for 1D and 3D systems modeling that includes varies computer and product data management (PDM) soft ware.

Flexible modeling design approaches with knowledge templates and best practices in manufacturing and assembly processes. Digitally mock-up of vehicle compartment enables design studies to be evaluated with different drive train configurations. Complex drive train structures can be digitally validated before actual production.

Complete Power Electronics Systems and Software Modeling 

Automotive OEMs and suppliers rely on electronics and embedded software as a key mechanism to control and manage drive train to meet design specifications. Traction drive systems must conform to algorithms of electronic control unit (ECU).

PLM software supports electronics and embedded software lifecycle with complete data model for all electronics, electrical, and software deliverables. The integration of the algorithms – control models – and proven vehicle-level models allow for front-load calibration process, essentially performing virtual calibration. These will significantly reducing the need for the costly prototyping and calibration.

Digital Manufacturing for Optimized Processes 

Electric vehicle platforms require flexible manufacturing to meet regulatory demands in specific market segment and customer’s expectations. Critical components must be assembled and work flawlessly in different climatic environmental conditions. Critical information on components tolerances, assembly sequence must be readily available. PLM Software’s digital manufacturing solutions shorten production lead-time and minimize quality issues.

Systems-Driven, Closed-Loop PLM 

PLM Software connects business with extended value chain; team members must have access to current data on drive train, battery lifecycle and critical components. The same product lifecycle management (PLM) system that manages drive train, battery system and product development can be used to predict and control product process flow and costs.

Workflow management capabilities enable entire value chain can be share throughout the lifecycle. Changes can be effectively evaluated for product enhancement, tooling, manufacturing and serviceability impact. Implementation with status reported and tracking can be consistent with the overall development timeline.

This systems-driven, closed loop approach allows automotive OEMs and suppliers to respond faster to changing market and regulatory demands.

The Premium Efficiency Motor- PEM motors – the superior substitute 

An increased efficiency represents the main competitive edge of the PEM drive concept when compared to induction motors. This can be leveraged for inner-city driving cycles of city buses. As a result of the magnets, a magnetizing current is not required in the lower motor speed range, therefore achieving significantly higher efficiencies.

Due to the high torque levels when driving and braking, these operating points have positive impact on the energy balance. This is compounded by the fact that for the same torque requirement, a PEM requires a lower current draw. Put briefly, the costs are reduced over the complete lifecycle. 

Technical advantages at a glimpse

ELFA: Technical advantages at a glance

  • There is no gearbox between the motor and rear axle

––Better overall efficiency

––Gearbox oil does not have to be changed

––Lower weight

  • Oil does not have to be changed (as there is no gearbox)
  • Modular system (identical parts for production,

power can be simply scaled based on the length)

  • Lower weight (as there is no gearbox)
  • Up to 50 % lower fuel consumption when compared to conventional drives and therefore lower lifecycle costs
  • Increased range of battery-powered electric vehicles using high efficiency PEM motors