Holistic Electric Powertrain Component Design for Battery Electric Vehicles in an Early Development Phase

As battery electric vehicles (BEVs) gain significance in the automotive industry, manufacturers must diversify their vehicle portfolios with a wide range of electric vehicle models. Electric powertrains must be designed to meet the unique requirements and boundary conditions of different vehicle concepts to provide satisfying solutions for their customers. During the early development phases, it is crucial to establish an initial powertrain component design that allows the respective divisions to develop their components independently and minimize interdependencies, avoiding time- and cost-intensive iterations. This study presents a holistic electric powertrain component design model, including the high-voltage battery, power electronics, electric machine, and transmission, which is meant to be used as a foundation for further development. This model’s simulation results and performance characteristics are validated against a reference vehicle, which was torn down and tested on a vehicle dynamometer. This tool is applicable for an optimization approach, focusing on achieving optimal energy consumption, which is crucial for the design of battery electric vehicles.