Electric Axles for Medium Duty Commercial Vehicles

Authors

J. Shutty, C. Kurmaniak, R. Blissenbach, H. Nanjundaswamy, P. Hegde - BorgWarner
US

Summary

The electrification of medium duty commercial vehicles presents a complex set of design challenges. Performance, efficiency, and durability must be achieved while ensuring that weight, size, and cost requirements are met. In this paper, we delve into the design and implementation of two eAxles for a range of medium duty trucks. We first address the key considerations for translating existing requirements for ICE-powered vehicles to electrically powered vehicles. For example, which performance requirements should be satisfied with peak torque and which with continuous. We also reveal which of the 100’s of requirements are the most critical in driving component selection.

The paper then outlines the optimization process at the system and sub-system levels, including the use of design, modeling, and simulation tools and techniques. The eAxle design is presented in detail, with component diagrams and simulated performance data. Finally, on-vehicle results of an eAxle applied to a 12,700 kg Gross Combined Vehicle Weight Rating (GCWR) dump truck are shared.