New Axle Makes Designing Hybrids Easier

The 2017 Volvo S90. (Image courtesy of Volvo.)

The 2017 Volvo S90 is a luxury sedan that launched this March as the reboot of the manufacturer’s S90 line from the 1990s. This week, GKN announced that its latest compact, high-performance eAxle will be featured in the S90’s hybrid-electric T8 AWD variant.

GKN’s most recent innovation allows its electric axle to be packaged into the same space as a standard rear drive module, facilitating integration into vehicles like the S90, as well as the previous Volvo XC90 T8 Twin Engine plug-in hybrid SUV. The S90 T8 will allow for hybrid all-wheel drive during which the eAxle runs in parallel with the combustion engine, as well as a fully electric rear-wheel-drive mode.

GKN Driveline has pioneered eAxle technology since 2002, seeking to improve efficiency and reduce size. Its developments include the use of Meshed Transmission Error processes to improve NVH, and disconnect clutch technology to increase efficiency when using the combustion engine. The company also developed a two-speed electric axle, manufactured for the BMW i8 plug-in hybrid sports car.

GKN’s most recent innovation allows its electric axle to be packaged into the same space as a standard rear drive module.

The S90’s eAxle provides a nominal output torque of 2400 Nm, taken from a 65 kW, 240 Nm electric motor with a nominal maximum input speed of 13000 rpm, through a two-stage single speed gearbox with a ratio of 10:1.

A 34kW engine-mounted integrated starter generator (ISG) improves fuel efficiency and the supply of power to the eAxle.

In a typical hybrid-electric vehicle, the electric motor and combustion engine both operate on the primary axle, requiring a power management device to regulate the energy provided. In comparison, the eAxle works by providing electric power to a vehicle on a secondary driven axle, in parallel to the primary axle which remains driven by a combustion engine.

GKN Automotive’s president of engineering, Peter Moelgg, calls the S90’s eAxle “the ultimate feel-good upgrade for consumers.”

As the market for electric vehicles grows, and consumers look to luxury brands to provide environmentally responsible options, hybrid module upgrades provide an option for those looking to explore the electric market without giving up the reliability of the internal combustion engine.

This technology also offers benefits such as improved fuel efficiency and a quieter driving experience. Compact electric motors like the GKN eAxle are a significant step forward for practical hybrid-electric cars, and will help drive forward the availability of hybrid-electric options for upcoming models.

Follow the links to learn more about the GKN eAxles and the 2017 Volvo S90.