Vitesco: e-Axle Control Module for efficient and compact electric drives

The Regensburg-based e-drive specialist Vitesco Technologies presented new technologies for electric driving at the recent CTI Symposium in Berlin that aim for more efficient driving, thereby increasing range, and a higher integration of individual components into modules. They claim to be among the successful pioneers with their EMR3 and EMR4 electric axle drives, offering efficient compact complete solutions for electric vehicle drive systems. In an innovation project, the company has now developed a prototype of the E-Axle Control Module. The electro-hydraulic control module, showcased for the first time in Berlin, provides several scalable functions. Essentially, the product offers oil cooling for high speeds, allowing the maximum power of an electric motor to be used as continuous power more extensively than before. Additionally, the module can supply oil for lubrication purposes. Further functions are planned to be integrated in three scalable expansion stages with additional actuators. These include safety functions for automated driving, the ability to "sail" without recuperation when the battery is full to save energy, and additional clutches for torque vectoring. A so-called "dry" rear axle with a purely electrically operated brake will also be feasible with this module.

"Higher functional integration, as we demonstrate with the E-Axle Control Module, makes electrified vehicles even more efficient and simplifies it for vehicle manufacturers to economically realize innovative features," promotes Thomas Stierle, member of the board and head of the two business units Electrification Technology and Electronic Controls at Vitesco Technologies, for the technology.

A second highlight is the showcased thermal management module. It integrates numerous individual components, such as actuators, sensors, and pumps, into a module that is easy to mount. This higher degree of integration saves seven percent of installation space in a sample configuration, reduces the number of individual components to be assembled by 75 percent, and can save up to approximately ten percent of costs, depending on the application. The core function of thermal management, the provider outlines, is to flexibly distribute heat flows within the vehicle so that all systems can operate with optimal efficiency. In winter, the thermal management ensures the battery is preheated before charging to enable efficient and fast charging. Efficiency was also the focus of the innovative battery management system showcased in Berlin. It takes over essential control functions for power optimization as well as the safety monitoring of the battery. With a proprietary process in the area of Active Cell Balancing, further system efficiency advantages can be realized through the battery management system. According to the specialist, there are already customer projects for both technologies.