In the rapidly evolving automotive technology landscape, our client aimed to lead innovation by integrating various e-powertrain components including an electric motor, power-electronics, transmission unit, and active cooling system into a single module “eAXLE” to minimize power loss and enhance efficiency. In traditional powertrain configuration, such components were placed separately, resulting in power losses, lower efficiency, and increased space utilization. This progressive technology significantly enhances aspects of operational efficiency, active cooling system, and space optimization. Additionally, the streamlined design of the eAXLE provides greater flexibility in the design of the vehicle.
However, owing to the primary objective of space saving the key challenge in developing an integrated eAXLE is to design components that fit the space requirements and an active cooling system that maintains or improves optimal performance and prevents overheating.
The Results
- Space & weight optimization: By integrating multiple components into a single unit the eAXLE has freed up space allowing more flexibility in design.
- Increased Efficiency: The incorporation of a heat recovery system has enabled the system to reuse the wastage heat more efficiently thereby improving overall vehicle efficiency.
- Cost Optimization: ~15% cost saving achieved by integrating components in one single unit thereby avoiding the necessity of additional components present in the traditional drivetrain unit.