Electric Drive Modules : Driving EVs further and faster

Automotive industry is in the middle of a disruption. The whole industry is advancing towards zero-emission target for an obvious reason. Transportation accounts for one-fifth of the global CO? emissions, of which the road transportation has the major contribution, three-quarters approximately.

The pressing fact is that the population continues to grow and demand for travel continues, after a hiatus of almost two years due to COVID19 restrictions and lockdowns.

The pressing need to curb the detriment of emissions by transportation sector had many governments across the globe set targets related to increasing fuel efficiency or reducing emissions, with the US and European countries at the forefront.

The figure below portrays the fuel efficiency targets by different countries.

The automakers’ quest to meet the targets led them to explore possibilities mainly in weight-reduction, and introducing fuel efficient engines or zero-emission vehicles. Research suggests that a reduction in vehicle weight by 10% leads to an improvement in fuel economy by up to 8%.

The Rise of Electric Vehicles & Electric Drive Modules

Having Electric Vehicles in the product portfolio, to no one’s surprise, have garnered priority of the automakers the worldwide.

The total number of e-Cars sold in 2021 crossed 6.5 million and is expected to grow rapidly in the coming years.

To make electric vehicles lighter, perform better and a viable alternative for customers, the OEMs have been working constantly on the upgradation of the structure, performance, weight, and more. One of the most exciting advancements in this way is the development of an EV Drive Module (eDM).

What’s eDM?

The automakers need efficient electric power train systems that can be easily integrated into the existing vehicle platforms to bring better performing electric vehicles to the road, cost effectively.

To meet this need, advance electrification solutions like eDMs are used.

An eDM is simply an integration of electric motor, transmission, and power electronics into one unit, making the entire system much lighter.

This integrated module helps in converting DC from the battery into AC and ensures necessary torque is supplied to the drive system.

Fig1 briefly depicts the functioning of an eDM in EVs.

   Fig 1. Functioning of eDM in EVs.

Benefits of eDMs

This ‘all-in-one’ modernised electric drive module system eliminates unnecessary mechanical interfaces, helping OEMs attain a remarkable reduction in the weight by 20%, size by 15% and cost by 30% approximately.

In a nutshell, eDMs offer the following benefits.

• Compact –A single unit holds together all the key components making the eDM compact and it thus offers flexibility in installation.
• Less emission – Electric drive modules significantly reduce exhaust gas and noise emissions.
• Lesser battery consumption - High system efficiency ensures greater electric range or alternatively lower requirements for battery capacity.
• Scalable – Both Battery Electric Vehicles (BEVs) and Plug-in Hybrid Electric Vehicles (PHEVs) can adapt this system according to different payloads.
• Cost efficient- eDMs’ integrated system saves the components and expensive connecting cables, further minimizing the price of EVs.

OEMs Leading the Pack

Owing to the several benefits offered by these compact modules, their penetration is rising in the EVs.

As on 2021, the annual sales value of eDMs was estimated at US$ 5.7 Billion. This figure is likely to be three times in coming 5-6 years’ time frame.

A major chunk of the global eDM sales is held by a few companies including mainly OEMs and a few tier players, with Tesla at the helm. Leading EV manufacturers like Tesla, Nissan, etc. rely on in-house capabilities to manufacture eDMs.

Listed below are few initiatives related to electric power train worth mentioning.

• As part of Nissan's midterm plan ‘Nissan MOVE to 2022’, the company plans to extend its leadership in electric vehicles, symbolized by the world's best-selling all-electric vehicle in history, the Nissan LEAF. The e-Powertrain in LEAF powers the EV and removes the need for an internal combustion engine. It is a lightweight, compact system that produces extremely low vibrations and generates instant torque.
• Likewise, the Tesla’s Model S, and Model X drivetrain unites powertrain and battery technologies for unparalleled performance, range, and productivity. Its new module allows faster charging and gives user more power and endurance in all conditions. The Tesla Model 3, also a compact executive sedan, was promoted as being more affordable to customers than its previous models. In June 2021, the Model 3 became the first electric car to pass one million global sales. Most of the Tesla models are e-passenger cars, in particular sedans and crossover vehicles, but plans to release Tesla’s first electric light-duty truck in 2022 are underway.
• Yet another giant - Volkswagen has introduced its EV platform titled – ‘Modular Electric Drive Matrix’ (MEB) based on which, the group plans to build 27 models across its four brands worldwide, by the end of 2022. All these new-gen vehicles are designed using high-performance batteries and modular designs.
• BorgWarner’s iDM146 integrated drive module (iDM) is set to power an additional ‘A Segment’ electric vehicle platform by Hyundai Motor Company (HMC), scheduled to start production in the 3^rd quarter of 2024. Its modular design allows power and torque output to be scaled specifically to customer requirements.
• American Axle & Manufacturing AAM’s e-drivetrain will power Mercedes AMG’s first plug-in hybrid electric (PHEV) model, GT 63 SE Performance. It will provide a power/torque output of 150kw/204 hp, adding performance in hybrid drive, and it will also help enable zero emissions.

Future plans of the Automakers are Exciting for eDM Market

It’s quite apparent and convincing with the sheer interest of the OEMs to replace conventional ICE engines with the electric ones. Let’s have a look at the electrifying expectations of a few automakers.

• Volkswagen revealed that half of its sales would be electric by 2030, and by 2050, the Group intends to operate fully climate neutral.

• Ford expects 40%-50% of its global vehicle volume to be electric by the end of 2030.
   
• Toyota, the largest car manufacturer in the world, has announced new investments aimed at achieving electric car sales of 3.5 million a year by 2030.
   
• Mercedes announced that from 2025, all newly launched vehicles will be fully electric.
   
• BMW aims for 50% of its vehicles sold to be fully electric by 2030 or earlier.
   
• Dongfeng, China’s leading automobile manufacturer plans to electrify 100% of its new models of passenger car brands by 2024.

Who leads the charge?

The increase in EV sales in 2021 was primarily led by China, which accounted for more than half of total new EV sales (53%). Sales volume of EVs with e-drive modules in China reached a total of 3.3 million in 2021, followed by Europe with 2.3 million and the U.S., reaching 630,000.

According to the China Passenger Car Association (CPCA), EV sales may reach 6 million units in 2022.

Other countries in Asia-Pacific region such as Japan, India, and South Korea also have promising growth prospects with a supportive policy framework and high ambitions. This space in Asian countries is worth watching for the next decade and will prove to be a huge market for eDMs.

The Road Ahead

The growth of the electric drive modules is closely linked to the demand for electric vehicles, and the road towards an EV future is not without potholes.

While the industry has a highly ambitious plan for EVs, the world is not prepared with enough charging infrastructure.

Adding to the misery is the exorbitant prices of Lithium due to shortage and rising demand. The upward trajectory in the price continues unabated in 2022 as well. It has hit the bottom line of the automakers hard. Recent investment plans of China’s EV giant BYD to buy Lithium mines in Africa reinforces the trouble which industry is facing.

The sudden spike in electricity prices in Europe due to the tumultuous political environment has made the future of EVs vulnerable.

Although the momentum created due to environmental concerns and favourable policies will likely keep the demand of the EVs soaring in the coming decade, however, the OEMs will have to revisit their strategies to keep themselves going.

The industry will be keen to compensate the rising input costs with innovations like eDMs. How it unfolds is no less than exciting.

Authored by Stratview Research and originally published on EE Power.