Magnetics Business & Technology - January/February 2021 - 14

FEATURE ARTICLE

Magna's e-Powertrain Solutions Provide Suite of Components and Systems for
Auto Manufacturers
Encompassing different
combinations of magnetic
technology, Canadian automotive supplier Magna is
building a suite of powertrains and components
for electric vehicles that
reflect its total systems
approach to serve the
evolving needs of automotive manufacturers. Shown
above is, e4, the company's latest technology demonstrator car
during winter test driving in northern Canada, which showcases
the new systems in a pure EV format.
The e4 includes highly integrated permanent magnet synchronous motor (PSM) electric drive systems on the front and rear
axle. The unit on the front is equipped with a mechanical differential, while the unit on the rear has a twin-clutch torque vectoring system. Both drives, including the gearbox, electric motors,
inverters, inverter software, and vehicle control strategy, are
developments from Magna. They deliver peak output of 180 kW
each with a high average efficiency of about 90 percent.
Launched this year, the e4 is the latest example of Magna's modular and scalable powertrain solutions for EVs. Its e2 prototype,
introduced a year earlier, allows a comparison of eight different
powertrain configurations within a single vehicle architecture.
Magna expects that global growth in e-mobility will include mild
and micro hybrids, high-voltage hybrids and electric vehicles.
" We are positioned to capitalize on the changing landscape
with a strong product portfolio that covers various powertrain
types, " said Tom Rucker, president of Magna Powertrain. " From
reducing CO2 and supporting sustainability goals to delivering
dynamic, fun-to-drive performance, we can lead automakers
through the powertrain transition with our modular and scalable
powertrain configurations. " Coming soon, said Rucker in April,
are all-wheel-drive systems from Magna that replace mechanical components with complete electric-drive powertrain systems
(motor-inverter-gearbox) and electric axles.
Magna continues to work on further optimization of e-drives with
a second-generation system, optimizing decoupling strategies,
winding technologies for the e-machines, and advanced electronic controls.
" The e4 demonstrates how cost, efficiency, and driving dynamics can be optimized without making any trade-offs " , says Harald
Naunheimer, vice president future products at Magna Powertrain. The efficiency improvements can benefit hybrid vehicles
as well as battery electric vehicles. For example, the rear axle
drive of the e4 can also be used in a high-voltage hybrid vehicle,
while offering the same efficiency and dynamics advantages.
Magna Powertrain uses a modular system of scalable building
blocks, which enables a high share of common parts. This applies to both electric axle drives (e-drives) and transmissions for
conventional and hybrid drives. For example, a common, stateof-the-art electric motor platform can be used for e-drives as well
as hybrid dual-clutch transmissions. All these applications can

Magnetics Business & Technology * January/February 2021

also utilize innovations like the decoupling of drives to further
increase efficiency.
" The scalability of building blocks and modular design allows
tailor-made solutions to meet a wide range of customer requirements, " says Anton Mayer, senior vice president engineering at
Magna Powertrain. " This applies both to OEMs, who can reduce
the consumption of their fleets, and to consumers, who benefit
from lower costs, greater range, and more driving pleasure and
safety. "
The company's high voltage portfolio covers a diverse range of
single components to complete systems, from mechanical eaxles up to highly integrated e-drives. Variations are available for
plug-in hybrids as well as for pure electric vehicles. Its platform
approach provides flexibility using cross-project synergies with
scalability from 50 - 250 kW.
Its Highly Integrated
eDrive System Low is
a small e-drive system
that contains either an
asynchronous motor or
a PSM e-machine, an
integrated single-speed
Highly integrated Edrive System from
gearbox and a high voltMagna
age inverter. The system's
power ranges from 60 to
90 kW. The Mid version includes a gearbox, a PSM e-machine
with 90-160 kW power and an inverter. It can be utilized as a
primary axle for battery electric vehicles or as a secondary axle
for full hybrid and battery electric vehicles. At the top of the range
is the High version with 160-250 kW power PSM e-machine,
inverter, and a torque-vectoring optional gearbox, designed for
high-performance battery electric vehicles.
Other avenues also are being explored by the company, including efforts to reduce dependence on rare earth magnets in EV
powertrains. In 2019, it was awarded a grant by the U.S. Department of Energy to develop advanced electric motor technologies
for next-generation vehicle propulsion systems. In partnership
with the Illinois Institute of Technology and University of Wisconsin-Madison, Magna is applying its powertrain, electronics
and full-vehicle expertise to deliver an automotive-grade, highperformance electric motor that aims to achieve increased power
density and reduced cost compared to current e-motors.
The objective is to develop an electric motor that is half the cost
and eight times the power density, while delivering 125 kW of
peak power. The reduction in cost is the result of eliminating
the use of rare-earth permanent magnets. To be presented for
evaluation in 2021, the project will integrate the electric motor technologies with a transmission and inverter as part of an
overall e-drive system. The project scope includes development
and use of innovative materials, cooling technologies, winding
technologies, simulation models, as well as control and optimization techniques.
For more info, see www.magna.com.

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Magnetics Business & Technology - January/February 2021

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