Next gen electric drive unit for passenger cars and light duty vehicles

This paper presents an advanced EDU family (Electric Drive Unit) with high system performance. Electric Motor, a new innovative gear set, differential, shift mechanism, dual inverter and cooling are integrated into one compact unit. Gear set and E-Motor inner cooling and lube are realized by a low power, cost effective centrifugal oil pump. The EDU features a water cooling for inverter and stator jacket.The compact gear set is realized as ring gear-less planetary structure with unique design. The complete reduction gear set is captured in one cage and is completely free of axial and radial forces (different than most today´s solutions). The gear set also includes a neutral shift and park lock system. Both systems are actuated by one electromechanical actuator. The park lock is in base principle a conventional park lock with claw, but realized with a multi claw pole in axial actuation to reduce weight and package space of the system.The high end version is equipped with a dual inverter. This allows the usage of a multiphase E-Motor (6 phase Motor is intended solution). In this way cogging torque can be improved without sacrificing efficiency. This gives even better prerequisites for good NVH behavior. As a further side effect the availability and scalability is improved by this approach.This next-gen EDU family shows very high specific values on System level. To achieve this many small and larger innovations were incorporated into the EDU system.