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In this paper, an electric drive unit (“central drive”) based on a novel dual-rotor radial flux motor technology is introduced. This motor technology increases the efficiency of electric drives while significantly reducing the cost of materials and manufacturing. The paper presents the fundamentals of the technology and outlines the specific advantages in terms of efficiency, performance, materials usage, and production. From a materials perspective, the very low demand for electrical sheet steel and the significantly lower magnet mass are particularly noteworthy. Combined with a cost-effectively integrated inverter, this motor technology forms the heart of an innovative central drive. Just like the underlying motor technology, the entire drive has been optimized for efficiency and low cost. This is achieved by a low-complexity, coaxial gearset architecture with just two gear pairs, a minimum number of bearings, all in fixed-loose configuration, and a well-optimized semi-passive lubrication system. Optionally, the central drive incorporates a unique roller-based park lock which eliminates the functional drawbacks found in conventional park lock systems.

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Efficient, Lightweight, Cost-Effective: Innovative Electric Drive Unit With Dual Rotor Electric Machine and SiC Inverter

  • 会议论文

  • 发表日期：

    2025年

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  • Alexander Rosen,
  • Vincent Berger,
  • Zoé Weicherding,
  • Gereon Hellenbroich,
  • Valeriy Shapovalov

摘要

In this paper, an electric drive unit (“central drive”) based on a novel dual-rotor radial flux motor technology is introduced. This motor technology increases the efficiency of electric drives while significantly reducing the cost of materials and manufacturing. The paper presents the fundamentals of the technology and outlines the specific advantages in terms of efficiency, performance, materials usage, and production. From a materials perspective, the very low demand for electrical sheet steel and the significantly lower magnet mass are particularly noteworthy. Combined with a cost-effectively integrated inverter, this motor technology forms the heart of an innovative central drive. Just like the underlying motor technology, the entire drive has been optimized for efficiency and low cost. This is achieved by a low-complexity, coaxial gearset architecture with just two gear pairs, a minimum number of bearings, all in fixed-loose configuration, and a well-optimized semi-passive lubrication system. Optionally, the central drive incorporates a unique roller-based park lock which eliminates the functional drawbacks found in conventional park lock systems.