Engineering
Beyond Net ZERO

eAxle Tier-1 Supplier Optimizes RFQ Response

Challenge
A Tier-1 supplier needed to respond to an OEM RFQ for EDUs across vehicle segments A–F. The objectives were to develop modular and cost-effective EDU solutions while minimizing energy consumption and hardware proliferation. Additionally, the supplier needed to meet stringent performance targets for WLTP efficiency, mass, and total cost of ownership.

Approach
Using ePOP, the supplier:

1. Aggregated Baseline Data: Imported RFQ specifications for top speed, acceleration, energy, and cost targets. Consolidated existing physical designs, virtual concepts, and new configurations.
2. Generated Concepts:
   • Inverters: Standardized CREE 1200V Silicon Carbide across all segments.
   • eMotors: Used PM 8-layer designs to meet performance needs.
   • Transmissions: Developed single- and two-speed systems with scalable gear ratios.
   • Simulated WLTP cycles, filtering configurations by energy efficiency, cost, and mass.
3. Simulated & Evaluated:
   • EDU1: Serves segments A–C with single motor, 2WD, and single-speed transmissions.
   • EDU2: Serves segments D–F with dual motor, 4WD, and two-speed transmissions.
   • Shared gear ratios within A–C and D–F for reduced proliferation.

Results

• Energy Efficiency: Common EDUs consumed <3.5 kWh, with segment bests at 2.5 kWh.
• Cost: Common EDUs stayed below $19,000, close to segment bests at $13,000.
• Performance: All EDUs exceeded top speed and acceleration requirements for their segments.

Conclusion
ePOP enabled the supplier to identify scalable EDU solutions that minimized costs, energy consumption, and hardware proliferation while meeting all RFQ requirements. This streamlined approach delivered a strong, competitive RFQ response.

Identify Electrification Opportunities for Off-Highway Powertrains

Challenge
An ICE supplier aimed to identify where electrification and hybridization deliver the greatest value in off-highway applications. Objectives included reducing fuel consumption, improving performance under load, and maintaining cost-effectiveness using existing component catalogues.

Approach
Using ePOP, the supplier:

1. Aggregated Requirements: Imported duty cycle, gradability, and acceleration targets; consolidated ICE, hybrid, and BEV components; set benchmarks for cost, energy, and versatility.
2. Simulated and Optimized Configurations: Modeled ICE, parallel hybrid, and series hybrid powertrains; evaluated EV-mode range, energy distribution, and fuel savings; optimized battery sizing and scalability for hybrid systems.
3. Identified Common Solutions: RWD ICE for high-torque simplicity; hybrid systems for fuel savings and adaptability; BEV solutions for low-duty or restricted emission zones.

Results

• Fuel Savings: Hybrid systems reduced consumption by up to 30%.
• Performance Gains: Improved acceleration under load by 15–25%.
• Energy Management: EV-mode range of 30–50 km in hybrid setups.
• Cost Efficiency: Leveraged existing components to minimize costs.

Conclusion
Hybrid systems delivered optimal fuel and performance gains, while BEVs were best suited for specific applications. ICE remained viable for high-load simplicity, enabling the supplier to balance electrification strategies and cost-effectiveness.

Quantify vehicle level KPI impact of more sustainable eMotor Materials

Challenge
A material supplier developing low-CO₂e metal powders faced challenges in demonstrating their value due to limited visibility into powertrain applications. Building physical prototypes would take years, delaying their ability to showcase material benefits to OEMs and Tier-1 suppliers.

Approach
Using ePOP, the supplier:

1. Aggregated Requirements: Selected the VW ID.3 as a benchmark vehicle and replaced stator laminations with SMC-based powders. Incorporated WLTP driving cycle data to simulate real-world impacts.
2. Simulated and Optimized Configurations: Tested various SMC powder grades for trade-offs in efficiency, power density, and CO₂e reduction. Iterated "what-if" scenarios for future material innovations.
3. Identified Common Solutions: Calculated range, weight, and CO₂e changes due to material substitution. Provided performance, cost, and sustainability trade-offs for OEMs and Tier-1 integrators.

Results

• Cost Reduction: Up to 10% manufacturing cost reduction.
• Sustainability: CO₂e reductions of 15% per motor.
• Time Savings: Shortened material development cycles by avoiding physical prototypes.

Conclusion

• Weight Reduction: Up to 10% in motor components.
• Sustainability: CO₂e reductions of 15% per motor.
• Time Savings: Shortened material development cycles by avoiding physical prototypes.

Conclusion
ePOP enabled rapid virtual prototyping, allowing the supplier to showcase the performance, cost, and sustainability benefits of its powders directly to OEMs and Tier-1 suppliers, accelerating adoption of its sustainable materials.