Volkswagen will introduce an improved EV drivetrain, built in the group’s components plant in Kassel, Germany in the fourth quarter of 2023.
The APP550 rear wheel drive system will give the brand’s ID. EV range a completely newly developed power unit with higher performance and improved efficiency.
First deliveries of vehicles with the new drivetrain in initial 210kW (286PS) form are scheduled for the “end of the year”, VW said.
The basic design is an evolution of the current modular electric drive (MEB) ‘matrix’ VW’s vehicle architecture tailored specifically for electric models.
Karsten Bennewitz, head of powertrain and energy systems in development, said: “Because the available space has not changed, we were compelled to develop a new drive that achieves significant improvements in performance and efficiency in spite of being subject to the same constraints.
“That was a great challenge for the technical development and group components teams.
“The result shows that we were able to reduce the use of raw materials, while at the same time achieving a considerable increase in vehicle efficiency.”
More power and “significantly” more torque
The new powertrain has maximum torque of around 550 Nm depending on gear ratio. VW claimed the “significantly higher torque in particular” ensures superior power development both from standstill and at higher speeds.
The new drive achieves its high torque thanks to an enhanced stator with a higher effective number of windings and a larger wire cross section. The rotor as its counterpart is equipped with a more powerful permanent magnet that has a higher load capacity. The drive was also reinforced to withstand the considerable torque produced.
Inverter delivers high current
Because current is a decisive factor for electric drive power, the latest inverter was developed to supply high phase currents needed for greater power and efficiency. It acts as the controlling ‘brain’ in the powertrain where functional software ensures efficient system processes. This applies to the clock frequencies and the modulation methods for generation of the alternating current for the electric drive motor. The drive motor can therefore operate more efficiently, depending on the load phase.
Optimised thermal management through intelligent cooling
To increase efficiency, VW also optimised other components including thermal management. The new drive consequently has an energy saving cooling system which operates without an electrically driven oil pump and is instead able to independently cool itself via the gear wheels in the gearbox and specially formed components for oil supply and distribution. Heated oil is cooled by the vehicle’s coolant circuit which keeps the drive at operating temperature. The outside of the stator is equipped with a water heat sink.
Kassel production
The drive system with gearbox, rotor and stator will be produced at the Volkswagen Group Components plant in Kassel.
Alexander Krick, technical development E-Drive, power electronics & transmission at group components said: “We have been developing electric drive motors and their gearboxes for 15 years now, and have also been producing them here at our location for over 10 years.”
Product and process innovations in the electric drive motor and gearbox result in a significant increase in efficiency and performance, VW claimed.
Krick again: “Drawing on our many years of experience, we optimised the overall system through the use of special electrical sheets and customised machining processes and were able to significantly increase efficiency.”
