07. February 2012

FEV announces new electric motor design, testing and integration capabilities

As vehicle propulsion systems increasingly incorporate electrical systems as supplementary or primary sources of energy, FEV takes the lead in e-motor/generator system design, testing and integration

Auburn Hills, Mich., February 7, 2012 – FEV GmbH, (FEV), and its global subsidiaries, leading developers of advanced powertrain and vehicle technologies, are evolving to support the increased investment by automakers around the world in electric and gas / electric hybrid vehicles. A recognized leader in traditional gasoline powertrains and driveline systems including transmissions, FEV recognizes that the near future of mobility will include significant numbers of vehicles propelled by electricity or a combination of combustible fuel and electricity. Its insight into such trends has allowed it to adapt its resources to better serve this rapidly growing segment.

“Energy is derived from many sources, and automakers are exploring all possibilities to incorporate these sources into automobiles,” said Prof. Stefan Pischinger, president and CEO of FEV GmbH. “Different markets will have different needs, but it is clear that in most global markets, the electric and electric hybrid vehicle has taken root and will soon become mainstream.”

Having established its reputation in powertrain development, it was a natural evolution for the company to incorporate electrical powertrain concepts into its capabilities. In addition to its battery development competence, FEV has now announced that it is offering complete electric motor design, testing and integration support to its global customer base.

E-Motor Design
FEV now offers all of the capabilities necessary to perform complete design and development of electric drivetrains. This includes CAE supported optimization of the electric motor, with a focus not only on the functional aspects, but also the NVH considerations that are necessary to minimize the noise excitation and radiation of the harmonic orders. FEV’s traditional transmission design and development teams work closely with the newly established e-motor teams to develop complete electric drivetrains.

For FEV’s customers, the opportunity to work together with a “one-stop shop” represents a significant advantage.

E-Motor Testing
FEV offers dedicated e-motor test cells that enable rapid electric motor and drivetrain functional testing. These specialized test cells accommodate the complete e-powertrain, allowing FEV’s engineers to accurately measure performance and efficiency of e-motors, or the entire e-powertrain thanks to high accuracy electric power and speed / torque measurement devices. E-motor control algorithm design, development and calibration are accomplished with automated testing and a battery emulation system.

The recently commissioned e-motor/generator test cells are uniquely configured to ensure that the e-motor and generator development effort results in a product that achieves maximum efficiency, performance, and durability. The new e-motor design, development and testing facilities allow:
• Controls development
• Functional testing
• Calibration development
• Performance testing
• Efficiency testing
• Thermal evaluation
• Durability testing
• Characteristic parameter measurement
• NVH optimization

E-Motor Integration
In addition to its design and testing capabilities, FEV has also developed an entire suite of e-powertrain integration capabilities. FEV engineers now offer all of the integration services that are necessary to support an OEM as they bring an e-motor or e-powertrain product into production, including packaging engineering, vehicle simulations to define the component specifications, thermal management, NVH and calibrations for drivability and performance.

FEV offers unique capabilities related to the management and build-up of prototype fleets including instrumentation of fleets for remote data acquisition and performance monitoring. FEV has conducted numerous projects to design, develop, integrate, and validate a group of prototype vehicles for use in closed fleets at customer locations.

The company offers e-powertrain target setting support to its customers. Due to extreme operating conditions and extensive use of the vehicles on a daily basis, it is important that fleet vehicles operate smoothly, efficiently, and be highly reliable. FEV engineers have extensive experience with durability and thermal investigations, beginning with initial prototype vehicles and continuing through fleet vehicles. This information is used to support FEV customers in the development of engineering targets for their products.

Similar to the traditional powertrain design, testing, and integration services that the company has become famous for, FEV now offers modern, high-technology facilities and capabilities that support its customers as they prepare new e-mobility products for the future.