GKN Driveline said it was transferring hybrid technology from super sports cars into affordable compact vehicles, having developed an eAxle module that will enable C-segment vehicles to offer buyers a plug-in hybrid option with improved performance and a reduction in CO2 emissions of more than 50%.

GKN Automotive president of engineering Peter Moelgg said: “GKN leads the industry in eAxle technology and we want to make plug-in hybrids a simple upgrade for consumers and manufacturers. With our systems now proven in halo hybrid sports car programmes and premium SUVs, automakers are working with us to launch eAxle technology in a much broader range of vehicles. Innovations by our hardware and software engineers will place the performance and efficiency benefits of plug-ins within the reach of many more motorists.”

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The new eAxle is an evolution of the system GKN designed for the Porsche 918 Spyder. The single-speed design minimises weight to just 20.9kg while optimising efficiency, installation space and costs for mass-market vehicle applications. A two-staged geartrain with a gear ratio of 12.5 provides up to 2000Nm torque and 65kW power for a dynamic pure-electric mode and balanced wheel torques for all-wheel drive mode. An electromechanically actuated dog clutch disconnects the electric motor at higher vehicle speeds and an open coupling minimises rotating losses when disengaged. Precision engineering of the gear teeth and other acoustic measures ensure noise emissions are minimal.

A typical C-segment plug-in hybrid could now have an engine output of around 100kW, with a GKN eAxle supplying an additional 65kW of electrical power. The eAxle can improve 0-100km/h acceleration times by several seconds, provide a useable pure electric range and reduce a vehicle’s CO2 emission rating to less than 50g/km.

Front-wheel drive vehicle platforms can integrate GKN’s compact, lightweight single-speed eAxle modules into the vehicle’s rear assembly to provide a combination of plug-in hybrid and electric all-wheel drive functionalities.

Rainer Link, GKN Driveline managing director of eDrive systems, said: “GKN’s position as the only hybrid technology supplier that can also deliver complete all-wheel drive systems makes us an ideal partner on these programmes. Our vehicle integration teams can support automakers in the tuning of their vehicle’s eAWD mode, ensuring that the torque delivery results in the right front-rear balance and delivers the brand’s trademark driving characteristics.”

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GKN has been pioneering the introduction of eAxle technology since 2002, launching the industry’s first high voltage eAxle applications with PSA Peugeot Citroen in 2010. The company was awarded Official Porsche Technology Partner status for its contribution to the plug-in hybrid 918 Spyder programme. It launched the world’s first two-speed eAxle in the plug-in hybrid BMW i8 and also supplies the eAxle on the Volvo XC90 T8 Twin Engine PHEV programme.