Powertrain Commonality across Vehicle Segments

Background

A customer responding to a major OEM RFQ needed to define a competitive EDU technology strategy spanning vehicle segments A through F. The RFQ emphasised modularity, low manufacturing cost, and reduced energy consumption – requirements that called for a high-fidelity, multi-dimensional trade-off study ideally suited to ePOP.

Project Objective

Identify the lowest-cost, highest-efficiency “3-in-1” eAxle architectures capable of forming a modular family that meets global automotive needs from 60 kW to 250 kW.

Approach

Using ePOP, multiple EDU concepts were evaluated with the goal of maximising segment coverage while minimising proliferation of motors, inverters, and transmission variants.
Each configuration was analysed for WLTP energy consumption, powertrain cost, and segment-specific performance targets, ensuring all architectures met required top-speed and acceleration metrics.

Outcome

The study delivered complete coverage across all vehicle segments with strong efficiency and competitive driving range. This was achieved through a streamlined architecture strategy comprising:

• A minimal set of transmission architectures and ratio variants
• A clarified and coherent motor roadmap
• Only two inverter types to support the full 60–250 kW spectrum

The result was a cost-optimised, highly modular eAxle family that satisfied the OEM’s RFQ requirements with minimal complexity.

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