GKN Driveline develops new e-drive system for PHEVs; starts production on global platform in 2019

GKN Driveline has developed a new, complete electric drive system for plug-in hybrid vehicles (PHEVs). The system will start production in 2019 on a global platform from a European vehicle manufacturer.

Tighter integration of electric drivelines improves system efficiency and gives automakers more packaging and assembly options. The new module integrates a water-cooled electric motor and inverter with a single speed eAxle reduction gearbox. The system generates a maximum 65 kW of power and can deliver up to 2,000 N·m (1,475 lb-ft) of torque to the rear wheels.

The complete eDrive module measures 300 mm high and 325 mm wide and weighs 54 kg (119 lbs), making it around 20 mm narrower and 2.5 kg (5.5 lbs) lighter than comparable systems. Despite significant differences in the acoustic signatures of the inverter, motor and gearbox, the overall system delivers a smooth, near silent electric driving experience.

This is the first all-in-one eDrive system to replace external wiring with a bus bar and to eliminate unnecessary mechanical interfaces. The result is an eDrive system with higher power density that is simpler to install.

—Peter Moelgg, Chief Executive of GKN Driveline’s eDrive and AWD business

GKN has been advancing the development of eAxle technology since 2002 and has produced more than 300,000 units at its manufacturing facilities in Europe and Japan. The company was awarded Official Porsche Technology Partner status for its contribution to the plug-in hybrid Porsche 918 Spyder program.

GKN launched the world’s first two-speed eAxle in the plug-in hybrid BMW i8 and also supplies the eAxle on the Volvo XC90 T8 Twin Engine PHEV program.

A new generation of vehicles is making hybridization integral to platform strategies. These complex drivelines require the higher levels of system integration that GKN eAxle electric drive modules deliver. By pioneering the development of these systems, GKN is positioned to help automakers turn electric propulsion into exciting new hybrid all-wheel drive experiences.

—GKN Driveline Chief Executive Phil Swash