ePOP system simulation software
Knowing where to start when defining the next generation of electrified propulsion system is a complex challenge. Proposing and committing to successful future strategies requires confidence, speed, and a detailed insight into the trade offs. ePOP is a fast and powerful offering designed to help you derive a competitive electric drive unit (EDU) strategy and solution. ePOP is a unique combination of process, toolset and experience which allows to embedd 3Dimensions into one problem simulation.
ePOP is a culmination of 5 years of work to help customers solve the Performance, Profit, Sustainability equation. All before investing major resources. That is what we call ePOP - Engineering Beyond Net Zero.
ePOP at a Glance
ePOP (Electrified Propulsion Optimisation Process) is a simulation tool based on a reduced order models (ROM). It helps designers and engineers make key decisions about powertrain architecture early in a project’s development.
By simplifying complex physical systems into compact, accurate models, ePOP allows teams to quickly explore different design options, weigh performance trade-offs, and test what’s feasible—well before building detailed models or prototypes.
Its fast results and solid physical basis help reduce risk, speed up innovation, and cut development costs. ePOP is also flexible enough to support a range of goals, including improving fuel efficiency, meeting emissions standards, designing hybrid systems, and testing control strategies.
The Concept Phase
ePOP facilitates Concept Exploration consolidating aspects of the entire design stage
Our software facilitates
Powertrain Optimisation Process
1.
Component
Library
2.
Requirements
Analysis
3.
Powertrain
Configuration
4.
Design Space
Exploration
5.
Shortlisting
and Decision
-
1. Setup Component Library
- Motor(s) / Engine(s)
- Transmission(s)
- Inverter(s)
- Battery(s)
- Component Generation
-
2. Requirements Analysis
- Vehicle, Wheel Torque
- Cycle, Speed
- Power, Packaging
- Vehicle attributes, sustainability
-
3. Powertrain Configuration
- BEV / ICE
- HEV Parallel / Series
- RWD, FWD, AWD
- Dual / Single motor..
-
4. Design Space Exploration
- Aggregated Powertrains
- Add Benchmark vehicles
dentit optimum - candidate along selected KPIs
-
5. Shortlisting and Decisions
Determine the optimal design
from a wide range of design
combinations.
How to get involved
A selection of ePOP White Papers
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2018, CTI Berlin
Electric drivetrain architecture optimisation for autonomous vehicles based on representative cycles
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2019 EVS32 Lyon
Gearing up for lower cost electric drives - Accelerating the development of optimal electrified powertrain architectures
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2019, CTI Berlin
Costly decisions creating product strategies robust to market instability and cost volatility
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-
Case studies
Examples of solutions in practice
Mid-Sized OEM
eAxle Tier-1
ICE Supplier
Material Supplier
Powertrain Concept Selection for a Mid-Sized OEM
Challenge
A mid-sized OEM needed to optimize the powertrain for their third BEV platform, balancing performance, sustainability, and cost. The goal was to evaluate existing components, consolidate inputs from sub-system design teams, explore new configurations, and identify the best Electric Drive Unit (EDU) for the target vehicle cycle.
Approach
Using ePOP, the team:
- Aggregated Baseline Data:
- Imported BEV platform requirements, eMotor, transmission, and inverter concepts to form an initial EDU.
- Generated Concepts:
- Scaled eMotors and created new topology concepts (e.g., Axial Flux, Radial Flux, PMSM, EESM).
- Designed transmissions with varying gear ratios and speeds.
- Added inverters from a library of power modules to diversify EDU options.
- Simulated & Evaluated:
- Analyzed losses at the EDU and subsystem levels (eMotor, inverter, transmission).
- Assessed KPIs such as mass, embedded CO2, range, top speed, and acceleration.
Results
ePOP enabled rapid evaluation of thousands of configurations, identifying optimized EDUs that reduced losses, improved sustainability, and met performance targets—all before investing major resources.
Conclusion
ePOP streamlined the OEM's BEV powertrain development, delivering data-driven insights and faster, more sustainable solutions.
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:
- Aggregated Baseline Data:
- Imported RFQ specifications for top speed, acceleration, energy, and cost targets. Consolidated existing physical designs, virtual concepts, and new configurations.
- 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.
- 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:
- Aggregated Requirements:
- Imported duty cycle, gradability, and acceleration targets; consolidated ICE, hybrid, and BEV components; set benchmarks for cost, energy, and versatility.
- 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.
- 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:
- 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.
- 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.
- 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.