E-mobility demands electric drive units (EDU) that deliver efficiency,
performance, and sustainability simultaneously. AVL addresses this with
two complementary concepts: the high-speed EDU for maximum power
density and the high-efficiency EDU with proven cycle efficiency above
94 %. Together with Design-to-CO2e methods and recycling strategies, they
cut weight, cost, and emissions.
he global shift to electric mobility is reshaping the
automotive industry. Customers want long range, short
charging times, and affordable vehicles. At the same
time, OEMs are facing mounting pressure to reduce lifecycle
CO2e emissions and manage scarce resources such as cop-
per, rare-earth magnets, and semiconductors.
AVL’s answer is to apply technology and the Design-to-CO2e
development philosophy. Instead of treating sustainability as
an afterthought, it becomes a guiding metric from concept
through production. Every design decision is evaluated in
terms of both environmental and economic impact. The out-
come is drive units that are competitive on cost, performance,
and sustainability.
High-Speed EDU: More Speed, Less Material
The principle is straightforward: higher motor speed allows for
smaller, lighter machines that use fewer active materials. AVL’s
high-speed EDU operates at up to 30,000 rpm and achieves a
system power density of more than 4.3 kW/kg.
In a 160-kW configuration, this results in 17 kilograms less
weight, around 8 % lower cost, and a 10 % smaller CO2e foot-
print compared with a conventional baseline system running
at lower speed. Key enablers include a two-stage transmission
optimized for efficiency, direct oil cooling, advanced hairpin
windings, and dual SiC inverters.
Looking ahead, the third generation aims to increase inverter
power density by 50 %. Single-motor variants could weigh
Driving Innovation
in E-Mobility
High-Speed and High-Efficiency EDUs
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