This presentation will showcase findings from a study aimed at identifying the most affordable and sustainable e-drive unit while maximizing efficiency. IAV systematically investigated all useful technology options for the main powertrain components e-machine and inverter within a parameter area of more than 100,000 different valid designs. The results show a lot of interesting effects and interactions between the four target KPIs cost, efficiency, carbon footprint and system mass, and the analyzed technologies, which will be showcased in the presentation. The study also demonstrated the excellent potential of phase change cooling (PCC) technology for EVs, with a remarkable potential for reducing e-machine size by over 25%. Particularly in vehicle applications requiring long-term, high-power operation, PCC technology can significantly improve cooling efficiency and reduce the size of active motor components.

Main takeaways:

• Phase Change Cooling technology as an enabler for the highest performance and efficiency
• Affordable e-axle systems with best-balanced KPIs
• Impact of voltage level, chip type, and e-motor material