Continental

First integrated electric axle drive for large-scale production

The powerful, lightweight and compact axle drive will hit the roads in China and Europe this year. It will be used in various electric models.

Continental plans to start series production of the electric drivetrain in China in the third quarter of 2019.

© Continental

In this case, "highly integrated" means that the new high-voltage drive combines the electric motor, power electronics and reduction gearbox in one housing. As these components, including the power electronics, have been matched to each other, the installation space and weight have been reduced: the axle drive now weighs less than 80 kg. The function of an electric parking lock has been newly integrated into the transmission. In addition, cable connections and plugs can be omitted, which lowers the cost level. This makes Continental 's drive division one of the few system providers able to offer a complete, electrified drivetrain from a single source.

The axle drive is available in two power levels with 120 or 150 kW. In terms of power output of up to 150 kW and maximum torque of up to 310 Nm, the new electric axle drive is comparable to a conventional 2-liter turbodiesel engine. The electric motor and power electronics of the new system are liquid-cooled.

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Suitable for various vehicle classes and concepts

The electricity for the electric heating of the catalytic converter can come from an efficient 48 V hybridization system. Continental has demonstrated on the chassis dynamometer with the 'Super Clean Electrified' diesel test vehicle that even the demanding 'London Traffic Cycle' can be met with the electrically heated catalytic converter: NOx emissions during this short cycle with many idle times (traffic jams), low engine load and many start-up processes were below 27 mg/km. At the same time,CO2 emissions fell by 4 g/km.

Continental's axle drive is suitable for numerous vehicle classes and concepts. Specifically, the drive module will hit the road this year in a European compact car and in several compact SUVs from Asian manufacturers. In addition to these new electric vehicles from traditional OEMs, the new Continental technology is also driving the 'Sion' electric vehicle from German start-up Sono Motors. The 'Sion' is the first series-produced electric vehicle with solar cells integrated into its body. This allows the car to produce its own electrical energy, which increases its range. Production of the car, whose electronic architecture is prepared for innovative sharing concepts, will begin next year. The partnership between Continental and Sono Motors is designed for the long term over the entire life cycle of the Sion.

Series production of the new global axle drive will begin in the third quarter of 2019 at Continental's plant in Tianjin, China. The reason for manufacturing in China is, on the one hand, the proximity to what is currently the largest and fastest growing market for electric vehicles and, on the other hand, the strong supplier chain that Continental has built up in China.

Many years of e-experience

As early as 2006, Continental began development work on an electric drive, which was used in an electric car from a European manufacturer from 2011. The new, third generation of the axle drive not only incorporated the experience gained from the electric drive, but also the experience gained from years of everyday use of this technology.

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