Agenda 2023

• Key finding from new vehicle experience study of Chinese and American EV buyers
• What technology solutions are coming that will improve the adoption of EV’s
• Will the new technologies have a significant impact on improving consumer sentiment?

Paul Haelterman, Vice President, Strategic Vision, USA

Dapo Adewusi, F150 Lightning Vehicle Engineering Manager, Ford Motor Company, USA

• Newly developed P3 e-drive
• 2-speed gearbox and electronical limited slip differential
• Performance results in practice and in-vehicle testing

Joe Mueller, Executive Director, American Axle Manufacturing, USA

• New benchmarks for range and dynamics
• Next generation e-drive systems
• Decoupling and functionality for more efficient electric vehicles

Dr Daniel Lindvai-Soos, Director, Product Management, Magna Powertrain, Austria

• Extensive application analysis based on advanced market data processing
• Family strategy definition for both layshaft and planetary architectures
• More opportunities for planetary configurations?
• Add-on systems: forced lubrication and park lock

Rahul Plavullathil, Head of E-Axle Mechatronics Department, Marelli Europe S.p.A., Italy

• Sustainability without compromise
• Reducing cost and improving efficiency
• Application-based motor optimization
• Advanced cooling concepts

Jonathan Getz, eMotor Customer Solutions, Schaeffler, USA

• BEV light commercial vehicle simulation and relevant cycles
• Motor simulation and tool-chain used in the electric machine design process
• Inverter selection
• Analysis of the different configuration vs efficiency, battery size and total vehicle weight

Daniele Zecchetti, Electric Motor Research and Development Director, Marelli Europe S.p.A., Italy

• System efficiency up to 97% and range increase up to 20% with the same battery capacity
• Low unsprung masses and no negative impact on driving comfort and safety
• High material utilization and very small magnet mass per torque

Dr Alexander Rosen, Co-Founder and System Engineer, DeepDrive GmbH, Germany

• Improved production techs for e-traction solutions
• Distributed high density (DHD) stator winding: An update
• DHD stator winding for 800V e-machines
• New rotor winding techs for high-performance EESM

Kumar Rajasekhara, CEO and President, Marsilli North America, USA

• Scalable stator production solutions – how to gain productivity
• I-Pin production
• What is not on the drawing – the importance of i-pin wire specification

Matthias Weber, Technology Lead E-Mobility and Test Equipment, Felsomat GmbH Co. KG, Germany

Byung-Ki Ahn, VP, Global Head of Battery Cells, Modules and Packs, Stellantis, USA

• Increasing all-solid-state battery internal particle conductivities
• Lowering the required stack pressure in all-solid-state battery
• Reducing the required stack-pressure by increasing internal particle conductivities in all-solid-state battery

Dr Rashid Farahati, Director Corporate Competence Center Americas, Schaeffler Group, USA

• State of charge estimation
• Kalman filtering
• Battery model calibration
• Cell testing methodology

Matthew Wise, Design Engineer, Schaeffler Transmission Systems, LLC, USA

• Pioneering technology with extremely safe high-power battery cells for up to 3.75 MW charging power
• FlashCharge battery for sprint and endurance e-motorsports
• Complex tests results

David Wollschlaeger, Engineer, hofer powertrain, Germany

• Patented new intelligent battery disconnect unit is an ultimately centralized solution
• New potentials in designing dynamic models considering performance releases, efficiency aspects, and driving behavior
• Scaling the savings potential through several battery packs in one system

David Wollschlaeger, Engineer, hofer powertrain, Germany

• Combined lumped-parameter and CFD analysis methodology
• Performance assessment of oil cooled electric motors
• Design exploration of oil cooled electric motors.

Robert Smyczynski, Head of Light Vehicle Innovation and Advanced Engineering, Dana Incorporated, Belgium

• Application overview
• Customer requirements and challenges
• Platform development

Alexander Reul, Manager – Advanced R&D, Buehler Motor, Germany

• Full-scale e-testing provides insight into lubricant impacts
• These capabilities allow development of meaningful e-tests
• New e-hardware test for system efficiency will be discussed
• New e-hardware test for thermal management will be reviewed

David Whitticar, Driveline Test Engineer – Electrification, The Lubrizol Corporation, USA

• Reflecting trends on adaption of ultra-low viscosity fluids for BEV
• Efficiency driveline testing with low and ultra-low viscosity fluids
• Formulating high performing fluids for electric racing

Torsten Murr, Global Technology Manager Transmission Fluids, Shell Global Solutions Deutschland GmbH, Germany

• Use of low-viscosity, low-volatility (LVLV) PAOs in next generation EV fluids
• Share insights on rapid development of BEVs, our view on future fluids requirements and demand
• Overview of new EDU designs and ways in which LVLVs meet EV fluid requirements

Dr Rohan Hule, Global Marketing Leader, ExxonMobil Product Solutions, USA

• Volume: Differential -60% vs. standard bevel gear type
• Width: Ball bearing -30%, oil seal -20% vs conventional
• Power density improvement especially for co-axial type e-axle
• Vehicle performance / efficiency improvement by LSD effect

Makoto Nishiji, Chief Engineer, Senior General Manager, Driveline Department, JTEKT Corporation, Japan

• Basic principle of eXD mechanics
• Control strategies to enhance EV driveline challenges
• Design challenges and opportunities due to packaging

Mattias Magnusson, Manager Vehicle Dynamic and Hannafia Spånberg, Director Engineering Europe, BorgWarner, Sweden

• TVTC design concept and specification
• TVTC torque characteristics: accuracy, spin loss and response speed
• Ride and handling characteristics on vehicle

Hosub Lee, Senior Research Engineer, Hyundai-Wia Company, Republic of Korea

• Challenges for actuation systems in electrified drivetrains
• Functionality of the smart hydraulic actuator and the modular architecture
• Comparison of the smart hydraulic actuator with the other actuation concepts

Christian Steinwandel, Chief Engineer eMobility, Schaeffler Group, USA

• Influence of machine gear topologies at NVH behavior
• Generating synthetic gear topologies with scripting
• Considering the production tolerances and machining
• Tooth contact analysis of machined and scripted topologies

Marcus Morgenstern, CAE Engineer, IAV GmbH, Germany

• Fault detection and isolation (FDI)
• Fault detection and isolation and reconfiguration (FDIR)
• Electric drive systems

Ahmad Ghaderi, Systems Chief Engineer, Dana Incorporated, USA

• Performance and new requirements on NVH test benches
• NVH testing of EDUs and their components
• New special measurement systems and high frequency analyses
• Future trends of NVH – and EMC testing

Dr Joschi Sucker, Head of NVH Testing and Technology, ATESTEO GmbH & Co. KG, Germany

• MBS model with flexible bodies, driven by electromagnetic forces
• Gear micro and macro geometry and detailed roller bearing representation
• MBS results and acoustic FEA used to generate radiated noise levels
• Comparison of noise levels to FEV’s test based scatterbands for EDUs

Joern Baumann, Senior Engineer, FEV North America, Inc., USA

• Achieving enhancements by optimization of the control strategy
• Application of system characteristic maps to determine the best load split
• Maximization of system reliability

Dr Michael Leighton, Technical Expert, AVL List GmbH, Austria

• Introduction: first highly integrated Dana off-the-shelf eDrive
• eS4500i platform: multiple options for multiple customers
• Highly integrated layout: a closer look at motor-gearbox integration

Marco Silvestri, Project Engineer, Dana, Italy

• iDM System target setting – Cost and Efficiency analysis of various system architectures
• Challenges and impact of high-speed electric motor to iDM system – Development analysis on innovative cooling system
• Compact iDM Design – Development of high-speed gearbox and highly integrated inverter

Andreas Mayer, Senior Lead Engineer – Advanced E-Motor and E-Drive Engineering, BorgWarner, USA

• HV e-motors with innovative form litz winding technology
• 3-level inverter for highest power density in PE
• HV booster – charging 800V systems at 400V stations

Thomas Hackl, COO, hofer powertrain, Germany

• Additive manufacturing to increase peak power & efficiency
• How to evaluate the CO₂-equivalent on an EDU
• Design-to-CO₂-eq & calculation of CO₂-eq over life cycle

Wilhelm Vallant, Product Manager, AVL List GmbH, Austria

• 500+ kW rear EDU with torque vectoring
• Packaging two motors in the space of one
• Latest inverter and motor technology developed for series production
• Real-time integrated development environment accelerated the development

Matthew Memmer, Director of Engineering, TREMEC, USA

• Growing market, growing voltages, growing current levels
• What could go wrong: EV system potential failure modes
• Safety solutions: advanced EV system protection and switching

Werner Happenhofer, VP Engineering, Eaton, USA

• Is an OBD diagnosis always correct? Causes of faults in the course of a battery repair
• Efficient repair of a traction battery
• SOH evaluation of battery modules for further use

David Pflanzl, Product Manager E-Mobility, AVL DITest, Austria

• What are the key performance indicators for running a lob on highest efficiency?
• How to process the generated data automatically without human interaction?
• How to manage energy consumption in realtime with prediction into the future?

Gerald Sammer, Principal Business Development Manager, AVL List GmbH, Austria

• Transfer functions reducing cell-level energy density
• Integration into modules and packs
• Energy density benchmarking across disparate battery designs

Andy Oury, Engineering Technical Leader – HV Battery Packs, General Motors, USA

• Rising demand for SiC in high voltage power electronics for EVs
• New concept of switching cell for the next generation of 800V SiC inverter

Sanjaka Wirasingha, R&D Director – Americas, Valeo, USA

• Manufacturing challenges of SiC from sand & coal to finished product optimized for EV powertrain
• SiC vertically integrated supply chain and scalability against market demand
• Reliability of SiC EV powertrain devices in high volume – intrinsic and extrinsic considerations

Dr Jeff Casady, Product Director, Wolfspeed, USA

• The functions and requirements of power modules in xEV applications
• Technical status of power modules, and key trends in substrates, interconnection, cooling, encapsulation materials, and electric designs
• Comparison between Si IGBT and SiC MOSFET modules based on in-house teardown studies on the latest modules on market (Denso, STMicroelectronics, Wolfspeed, etc.)

Dr Yu Yang, Senior Technology and Market Analyst, Yole Intelligence, France

• On-board charger integration with DC/DC converter
• Common transformer core for OBC and DCDC functions
• High power density OBC/DCDC

Bob Li, Chief System Architect, Ricardo Plc, USA

• Emission regulations and the inflation reduction act – Pushing e-mobility in the CV business
• Ambitious zero emission targets of major OEM and how they want to tackle the targets set
• Electrification penetration rate for HD CV
• Charging hardware echnologies pushing the electrification penetration rate

Simon Buderath, Principal Strategy and Technology, P3 USA Inc, USA

• Drive cycle comparison for heavy truck hybridization
• Heavy truck hybridization options
• Reduction of emissions through heavy truck hybridization

Gustavo Gomes, Program Manager, Schaeffler Group, USA

• Innovative central drive and e-axle systems for medium and heavy-duty vehicles
• Introduction of modular e-powertrain platform components
• Technology outlook on e-motor and power electronics

Robert Levy, Technical Specialist, ZF CV Systems North America LLC, USA

• Next generation EV platforms, ready to carry the future of E-mobility: flat, scalable and modular providing maximum efficiency and full design freedom
• REEcorner technology with drive-by-wire, steer-by-wire and brake-by-wire capability
• REEboard technology: a completely flat and modular electric platform

Dario Bignamini, Head of Project & Engineering Management, Chief Engineer, REE Automotive, UK

• Improving Efficiency, Performance, and Driving Experience with Sigma’s Electric Powertrains
• Sigma Powertrain Products & Technology
• PowerSplit Dual Mode (PSDM)

John Kimes, Founder & CEO, Sigma Powertrain, USA

• Detailed examination of the strategies of OEMs from consumer electronics
• Impacts on the e-axle and potential integration of other systems/controllers
• Future mode in BEV: enclosed chassis and contract manufacturing

Dr Yu Yang, Senior Technology and Market Analyst, Yole Intelligence, France

• Cost focus transition from ICEs to electric drive systems
• Cost impacts of over-specified system functions
• Cost structure of the inverter and the main cost influences

Jeffrey Musson, Head of Systems Development, GKN Automotive, USA

• TMR – new sensing technology optimized for the use at speed sensor
• Higher accuracy and flexibility in magnetic circuits and module design
• Rotational speed sensor
• Functional safety

Yunfeng Li, Senior Application Engineer, Infineon Technologies Austria AG

• Evolution of shift systems and the transition to EV drivetrains
• Challenges and needs for next generation EV drivetrain systems
• New powershift technology with integrated one-way-clutch functionality
• New multi-functional torque management systems for disconnect and multi-speed shifting

John Jennings, Director of eMobility and Innovation, Amsted Automotive, USA

• Clutch based torque distribution in the BEV powertrain
• Effect of efluids on tribology and material formulation
• Application specific material requirements

Christoph Hagauer, Engineering Manager ePowertrain, Miba Frictec GmbH, Austria

• Test methods for vehicle range determination
• Test methods and case studies for electric drivetrain efficiency evaluations
• Vehicle thermal management and influence to driving range

Tom D’Anna, Director, eMobility – Validation & Controls, FEV, USA

• Dynamic vehicle simulation toolchain using MATLAB/Simulink
• Modeling of electric drives for light-duty vehicles
• Validation of vehicle models with real-world data
• Data-driven optimization for powertrain components

Sandeep Saini, Sr. Staff Systems Engineer, Technology & Innovation North America, Vitesco Technologies, USA

• High-speed electric motor technologies
• Reduction of critical materials and recycling of electric motors
• Torque vectoring control improves stability, safety and increases vehicle dynamics
• High-speed 500 kW electric drive unit with 4.3 kW/kg power sensity

Mathias Deiml, Center Leader, AVL Software and Functions GmbH, Germany

• Creating a digital twin that actually works
• Setting up the communication infrastructure
• Challenges, solutions, results and future prospects

Lou Long, Business Development Director, Hexagon, USA

• System complexity drives need for digital twin approach
• System modeling performance and thermal behavior of integrated inverter, e-machines and axle
• Mission cycle sensitivity on thermal behavior and system performance
• Correlating digital twin models using design development tools and bench data

Dr Matti Vint, Director Vehicle Electrification, Marelli North America, USA