E-POWERTRAIN

AE Project
MECHANICAL STANDARD

Reference AE411.TCH.20.006 02 Customer PININFARINA

Date 25/03/09 Project AE BlueCar
Author David di Pelino Code ME5

For Company Copy to Company

F. IENNARO PININFARINA L. LEFEBVRE MATRA
P. SEGLIE PININFARINA L. HUCHET MATRA
C. TOSCANO PININFARINA FX. GERBEAUX MATRA
L. PERRIER BATSCAP G. CHELARD MATRA
J. ROYER ACTIA J-L. ROBINO MATRA
X. GREBILLE ACTIA B. HUREL MATRA
D. CALMETTES LEROY SOMER P. NARAT ACTIA
M. GALAIS LEROY SOMER D. CONDAMIN LEROY SOMER

Parts concerned Pininfarina Reference number

Assembled e-Powertrain 220 94 000
Electrical Motor 220 94 002
Controller 220 78 770

Index Purpose Comments Written by Date Checked by Date

To be confirmed
01 Creation L. Charbuy 20/03/09 D. di Pelino 20/04/09
A. Chantepie
D. di Pelino
02 Update Packaging L. Charbuy 24/04/09 D. di Pelino 30/06/09

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Table of Content
Glossary .................................................................................................................4
1. Mechanical Functional definition.......................................................................5
1.1. Pupose of the document ................................................................................................ 5
1.2. Life situation ................................................................................................................... 5
1.3. Mechanical Functional diagram...................................................................................... 6
1.4. Mechanical Functions to follow up :................................................................................ 6
1.5. FP1 : Generate mechanical torque and power by using battery energy and transmit it to
the reduction gear to respect vehicle drive comfort performance. Generate electrical energy by
using mechanical energy during deceleration............................................................................ 7
1.5.1. Torque performance required ................................................................................................ 7
1.5.2. Durability ............................................................................................................................... 8
1.5.3. Torque ripple.......................................................................................................................... 8
1.6. FC1 : Is integrated in the under bonnet packaging......................................................... 9
1.7. FC2 : Is connected to the wiring harness (High Voltage & low voltage) ....................... 10
1.8. FC3 : Fix harnesses ..................................................................................................... 12
1.9. FC4 : Is connected to the reduction gear ..................................................................... 14
1.10. FC5 : Is connected to understructure car body............................................................. 15
1.11. FC6 : is connected to cooling system ........................................................................... 17
1.11.1. Connection geometry ........................................................................................................... 18
1.11.2. Cooling loop characteristic .................................................................................................. 18
1.11.3. Technical requirements on the Powertrain .......................................................................... 19
1.11.4. Data to be provided by supplier ........................................................................................... 19
1.12. FC7 : Support accessories ........................................................................................... 20
1.12.1. Charger................................................................................................................................. 20
1.12.2. Water heater (water PTC) .................................................................................................... 22
1.12.3. Compressor A/C bracket...................................................................................................... 23
1.12.4. 280V DC/DC Converter : ................................................................................................... 24
1.12.5. Heating water pump ............................................................................................................. 24
1.13. FC8 : meet NVH requirements ..................................................................................... 25
1.14. FC9 : Withstand to exterior conditions.......................................................................... 25
1.14.1. Temperature ......................................................................................................................... 25
1.14.2. Humidity/condensation : ...................................................................................................... 26
1.14.3. Corrosion.............................................................................................................................. 27
1.14.4. Projections............................................................................................................................ 27
1.14.5. Fording and global tightness requirements .......................................................................... 27
1.14.6. Breathing.............................................................................................................................. 28
1.15. FC10 : Respect regulation............................................................................................ 29
1.16. FC11 : Meet crash requirements .................................................................................. 29

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1.17. FC12 : Meet assembly plant constrains ....................................................................... 29

2. Reliability........................................................................................................31
2.1. Durability target: ........................................................................................................... 31
2.2. Duty cycle..................................................................................................................... 31
2.3. Static Acceleration........................................................................................................ 31
2.4. Thermal shocks ............................................................................................................ 31
2.5. Vibrations resistance .................................................................................................... 32

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Glossary

o Electrical machine = Motor - Generator

o Controller = Inverter + 12 V DC/DC converter + supervisor

o Powertrain = Electrical machine + Controller

o Assembled e-PWT = Powertrain + reduction gear

o Equiped Powertrain =
Powertrain assembled + charger + water heater + water pumps and hoses + wiring harness + engine
mounts + A/C compressor with its bracket

o Traction System =
Equiped Powertrain + HV Battery + Supercapacitor + HV wiring

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1. Mechanical Functional definition

1.1. Pupose of the document

The purpose of this document is to define all the mechanical aspect and recquirement of the powertrain,
that is to say :
- The global characteristics of the powertrain
- The packaging and the interface requirement
- The cooling requirement
- The reliability

1.2. Life situation

- LS1 : Manufacturing
- LS2 : Storing and transport
- LS3 : Assembly on production line
- LS4 : Rolling
- LS5 : Chock
- LS6 : Aftersales
- LS7 : Recycling and end of life

Only LS2,LS3, LS4 and LS5 are described in this document.

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1.3. Mechanical Functional diagram

HIGH VOLTAGE UNDER BONNET

WIRING TRACTION PACKAGING
HARNESSES
PLANT

FC12 FC2 FC1

CRASH FP2
HARNESSES
FC11
FC3

REGULATION MOTOR
FC10
+
CONTROLLER FC5
UNDERSTRUCTURE
FC9
CAR BODY
EXTERIOR
ENVIRONMENT
FC6

FC8 FC4 FC7

NVH REDUCTION COOLING SYSTEM

GEAR ACCESSORIES

1.4. Mechanical Functions to follow up :

- FP1 : Generate mechanical torque and power by using battery energy and transmist it to the
reduction gear to respect vehicle drive comfort performance. Generate electrical energy by using
mechanical energy during deceleration.
- FC1 : Is integrated in the under bonnet packaging
- FC2 : Is connected to the wiring harness (High Voltage & low voltage).
- FC3 : Fix harnesses
- FC4 : Is connected to the reduction gear
- FC5 : Is connected to the understructure car body
- FC6 : Is connected to cooling system.
- FC7 : Support accessories
- FC8 : Meet NVH requirements
- FC9 : Withstand to exterior conditions
- FC10 : Meets all regulation requirements
- FC11 : Meets crash specifications
- FC12 : Meets assembly in factory requirements

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1.5. FP1 : Generate mechanical torque and power by using battery energy and transmit
it to the reduction gear to respect vehicle drive comfort performance. Generate
electrical energy by using mechanical energy during deceleration.

1.5.1. Torque performance required

The main function of the power train is to provide mechanical torque and power as described below :

Parameter Min Typical Max Resolu Unit Comment/condition

tion
Output Torque 98 140 Nm Maximum torque reached
at +/-2%

Power 35 50 kW Mechanical power (Pu)

reached at +/-2kW

Efficiency * 94 % The best efficiency area is

showed in green on
following graph

Motor + inverter max efficiency From 3500 The closest as %

to 5000 Rpm and from 10 to 50 Nm possible from 100
Maximum motor speed 0 12000 rpm

Mini torque @ 10000 rpm 48 Nm

Nominal Torque @ 0 to Pmax 98 Nm

Peak Torque @ 0 to Pmax 140 Nm

Max ripple torque ±5%

Frequency Dynamic performance on the 2%? Target hard to define => to
torque evaluate on prototype
Continuous mech. power for max vehicle 35 kW +5kW / - 0 kW
speed @ max motor speed & normal voltage
depending of existing motor
range
Max mech. power @ max motor speed & 50 KW Tolerance ± 5kW
normal voltage range (for an eventual carry-over pwt)

Dimension See attached allowed volume

* Best efficiencies will be at least 94%.

An efficiency map of motor alone, inverter alone and both motor + inverter will be provided by supplier.

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1.5.2. Durability

Performances of the powertrain has to be maintained during the complete life of the vehicle. This point is
explained in the section reliability.

1.5.3. Torque ripple

Max acceptable cogging torque whatever motor speed is: 5,4 N.m i.e.3,9% of the total available torque.
Acceleration variation felt by passengers is about 0,15 m/s², which corresponds to a torque ripple of 6,7
N.m.

As a consequence, the max acceptable torque ripple is 5% of the max torque whatever the motor speed.

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1.6. FC1 : Is integrated in the under bonnet packaging

The assembled e-powertrain is constituted of the electrical machine (Motor + ECM) and the reduction
gear.
The powertrain support additional component (A/C compressor, water pumps, air vacuum pump, battery
charger, water pipes, wiring harness…).
The powertrain will be mounted in the front motor bay. It will be linked with car structure through 3
brackets and pads, in a classical pendulum suspension design. (1 fixation on the inverter, the 2 other on the
reduction gear).
X
Front Member

Front Member
Reduction
Motor +
Y Z gear
Inverter

Dimension in Y axis has to be strictely respected, because the front side members are already fixed.
Volume : See 3D datas for allowed volume

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1.7. FC2 : Is connected to the wiring harness (High Voltage & low voltage)

This function describes the electric connection of the wiring harness on the powertrain.

High voltage is provided through BUS-BAR.

The high voltage wiring harness is not the responsibility of the supplier.

BUS-BAR connections:

- Ø6 : PTC & E-Compressor (Fuse protection, TBC)

- Ø8 : High Voltage Traction
- Ø6 : High Voltage Charge
- Ø6 : + 12V battery (Fuse protection TBC)

For signal and low voltage a connector will be used

High Voltage charge

Wiring harness (Battery Pack link)

HV Charger link High Voltage Traction

(Battery Pack link)

Cover

Fuse Box for 4 (12 V)

fuses

12 V Battery
charging
Water Heater
power supply
A/C compressor
power supply

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Fuse Box

12 V
area
Area usable to install the 12 connectors
Type and shape of connectors to be agreed

Electrical interfaces on ECM are described below :

- 12 V connectors to be installed in the defined area (to be specified on drawings by supplier)
- Connections on the internal bus bar (to be specified on drawing by supplier) :
 HV charge
 HV charger link
 HV traction
 HV A/C compressor power supply
 HV Water heater power supply
 12V charger battery charging
Those internal connections implies that water tightness is done between associated harness, ECM
housing and ECM cover with a tightness ring.

Technical requirement on connection :

 Connectors and connection on bus bar has to resist to a traction force of 50 daN in
all directions without loss of tightness.
 Water tightness IP65
 Interfaces have to resist to assembly/disassembly stress

Electric connections will be recognizable or equipped with a foolproof device to prevent from connecting
mistake.

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Service :
A security cover will be fixed with specific screws preventing customers to access to high tension cables
and with a warning message at the top to inform about.

Fuse Box :
- For serviceability the fuse box cap has to be accessible easily without tool. The fuse box will
content 4 fuses for:
 Rear drive lights
 Cooling fan
 12V network
 Reserve for adding fuse

1.8. FC3 : Fix harnesses

With its central position in the engine bay, the power train would be used to fix the different harnesses as
described below.

- 7 interfaces for motor harness clip : hole 6,5mm diameter on a nerve thickness 0,7 to 3mm (see
image below H1 to H7)
- 2 interfaces for 12V battery charger harness and HVAC compressor harness : slot 6,2x12,2mm,
2mm thick (see image below S1 and S2)
- 1 interface for HV wiring harness : M6 hole (see image below M1). Screwing torque : 8N.m +/-
20%
- 1 interface for ground link fixation : M8 position to be confirmed. Screwing torque : 21 N.m +/-
20%.
- 2 interfaces for HV wiring harness (charger…) : to be defined

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S1
X=-309 mm H6
Y=160,2 mm
Z= 313,5 mm

X=-309 mm
Y=160,3 mm H7
Z= 277,4 mm
S2 H5 2 Fixing points for wiring
harness

H1

H4

HARNESSES FASTENINGH3WILL BE UPDATED WHENGround

LAST link
HARNESSES DEFINITION WILL BE KNOWN fixation
H2

M1 X=64,4 mm
Y=193 mm
Z= 91,4 mm

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1.9. FC4 : Is connected to the reduction gear

The interface with the reduction gear is realized by 9 fixing points + 1 orientation point + 1 centring
diameter. Link will be insured by 7 screws M8X125-60 and 2 screws M8X125-40.
The tightening torque is 21 Nm ± 20%.
Motor will have to be able to mate easily with reduction gear axle defined below without generate noise,
jolts and premature wear for the vehicle life.

∅271

1 Not threaded through holes ∅8,2

depth 15 mm mini (locating for
Centring
reduction gear orientation )
diameter ∅215
Screw M8X125-60
for motor /
reduction gear

6 Not threaded through holes ∅9

depth 15 mm mini
Screws M8X125-60

2 Not threaded through holes

∅9 depth 15 mm mini
Screws M8X125-40

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Motor axle interface with reduction gear

1.10. FC5 : Is connected to understructure car body

3 Fixing points
z
Treaded holes x

M10X150
y
Depth 26 mm
mini

Inverter bracket Forces application

Force application point (R)
X=-145,1
Y=417,6
Z=267
Stiff links

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The powertrain is linked to the understructure car body with the ECM bracket. Interface requirement :
- 3 nonaligned bosses on the ECM (vertical screws mandatory). See CAD data and 2D drawing for
position. Boss diameter is 24mm and surfaces are raw.
- 3 threaded holes M10X150 on bosses with a depth of 26 mm mini
- Bosses stiffness : 10 8 N/m.
- accessibility by the screw driving machine with a socket external diameter of 24 ± 2 mm.

Threaded connection (tightening torque is 60N.m +/-15%) :

- no sliding under normal force and incidental force
- no matting of the material
- stress loss < 40%

The forces to applied at the interface (point R) due to vehicle using solicitation (torque reaction , road
solicitation…) is given into the following table :

Load case Fx Fy Fz
Static Normal 0 0 600
Bump Normal 0 0 1800
Incidentel 0 0 3000
Accidentel 0 0 5400
Rebound Normal 0 0 -600
Incidentel 0 0 -1800
Accidentel 0 0 -3000
Forward running Normal -800 0 600
Incidentel -1200 0 600
Accidentel -2450 0 600
Reverse running Normal 850 0 600
Incidentel 1300 0 600
Accidentel 2700 0 600
Lateral +g Normal 0 -600 600
Lateral –g Normal 0 600 700
Crash Accidentel 6000 0 600

A static computation has to be realised to proof the right sizing of the different housing of the power train.
For computation, the Power train has to be considered on embedment at the motor / reduction gear
interface and force is applied from point R to the 3 boss by using stiff link (typeRBE2/ Nastran).
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Acceptance criteria for static computation :

Von mises stresses < durability limit of the material under normal load case (generally Rp0,2/2)
Von mises stresses < elastic limit of the material under incidental load case (Rp0,2)
Von mises stresses < mechanical limit of the material under accidental load case

The interface has to resist to different durability test and vehicle running test described in section
reliability
The following durability cycle profile has to be achieved from interface point of view (with force data
applied at point R) :

1.11. FC6 : is connected to cooling system

This function described the requirements concerning cooling system from geometric point of view as well
as functional point of view.

The powertrain is cooled by a standard coolant (Mix of 50% water and 50% glycol).
Automotive standart coolant dynamic viscosity:
µ = 4,2.10-3 kg.m-1.s -1 @ 20 °C
µ = 1.9.10-3 kg.m-1.s -1 @ 50 °C

The inlet & outlet position are defined in the functional volume (CAD data) supplied with this Technical
Description.

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Coolant inlet in the inverter

Position can be moved but have to stay on
the blue area

Coolant outlet in the motor

Position and orientation can be moved but
have to stay on the front of the vehicle

1.11.1. Connection geometry

Inlet and outlet ends definition will have to meet ends standard defined in a separated document :
AE411.TCH.20.007 - Cooling Ends Standard Drawing. ∅A= 20 mm.
For packaging inlet and outlet ends might be covered with dust cap.
A free space have to be respected arround each ends to allow operators to hand-mount the collar rings
and tighten them (pinch tool).
Pipe orientations and positions are defined on the functional volume but they can be moved with our
design office agreement if it can simplify the manufacture.

1.11.2. Cooling loop characteristic

Parameter Min Typical Max Resolu Unit Comment/condition

tion
Flow 1200 1200 1200 L/h

Max inlet coolant temperature 55 °C @ 43°C T° ext

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1.11.3. Technical requirements on the Powertrain

Parameter Min Typical Max Resolu Unit Comment/condition

tion
Flow : Reynolds number 5000 without Turbulent

Pressure drop of coolant circuit 250 mbar @ 1000 l/h, 50°C

Inverter must be operating without derating 60 °C @ 43°C T° ext
until max coolant temperature
Max input coolant temperature without 75 °C In any case
damage (derating accepted) (misuse)
Heat rejection (continuous motor rating of 35 kW TBD by the
KW) supplier
Heat rejection (continuous motor rating of 50 kW TBD by the
KW) supplier

Erosion and Internal corrosion :

The loop will have to resist to a water flow of 1500 l/h at 60°C during 7000 h without leakage and
without internal corrosion able to destroy the water pump of the vehicle.

Internal cleanliness :
Deconnectable particles during the vehicle life must be < 0,35 mm and < 3 g per liter.

1.11.4. Data to be provided by supplier

The cooling system definition (radiator and pump) is based on an estimation of the thermal power rejected
by the powertrain.
A table of thermal power rejected by power train for engine torque from –140 to 140 N.m increasing by
10 N.m and for rotation speed from 0 to maximum speed increasing by 500 tr/min has to be provided by
supplier

Volume:
Internal volume value will be written on the drawing.

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1.12. FC7 : Support accessories

With its central position, the e-powertrain will support several accessories. This section concern only
physical interfaces.
Generally, interfaces position are included into CAD data provided with this mechanical standard.
The interface sheet are available in appendix.

1.12.1. Charger

The HV Charger (15 kg) is fixed on the power train.

The fixing system has to be designed to maintain the charger in position without any movements or
vibrations (no noise allowed).
The charger has to be removable without removing the powertrain from the vehicle.

2 Charger
fixing points with screws
M6X100

3 Intermediate bracket charger

fixing points with screws
M6X100

Accessibility for the screw driving machine (socket external diameter of 21 mm ± 2 mm) has to be taken
into account

Moreover to permit to keep standard and/or compact parts (charger-motor-inverter) it was chosen to create
2 intermediate brackets to fix them together.

 Charger main fastenings : 4 screws M6X100-20 with an access without power train demounting.
The tightening torque is 8 Nm ± 20%.
Need:
o 2 M6 threaded holes with a minimum depth of 20 mm on controller side
o 2 not threaded through holes on the intermediate bracket on motor side.

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 Charger intermediate fastenings: 5 screws M6X100-20. The tightening torque is 8 Nm ± 20%.

Need:
o 3 M6 threaded holes with a minimum depth of 20 mm on motor
o 4 M6 threaded holes on charger

Intermediate bracket fixed in first

on motor with 3 screws M6X100

Positions to define
with supplier

Intermediate bracket fixed in first

on charger with 2 screws M6X100

Final charger fastenings

orientation with 4 screws
M6X100-20 (Main fastening)

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1.12.2. Water heater (water PTC)

The water PTC is fixed on the motor with 4 screws M6X100. 4 threaded bosses of 20mm diameter and
minimum 19 mm depth are required. A flatness of 0,5 mm between the 4 bosses is also required.
The tightening torque is 8 Nm ± 20%.
The weight of the water heater is 3 kg.
Accessibility for the screw driving machine (socket external diameter of 21 mm ± 2 mm) has to be taken
into account.

PTC gravity center

X= -112,37
Y= 59,38 4 Threaded holes M6X100
Z= 309,85 depth 18 mini

Stiff links

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1.12.3. Compressor A/C bracket

Force application point (S):

X= -251.913
Y= 45.729
Z= -64

Z
Forces application
X

3 Threaded holes
Y M8X125 Depht 25 mini
Stiff links

The compressor bracket is fixed at the bottom of the motor with 3 screws M8X125.
3 threaded bosses of 20 mm diameter and with a minimal depth of 25 mm are required
The reception stiffness have to be > 10 8 N/m.
The tightening torque is 21 Nm +/- 20%.
Screws have to be accessible by the screw driving machine with a socket external diameter of 21 mm.
Bosses have to support A/C compressor with its bracket (total mass = 7 kg) without damage during all the
vehicle life.
The position of the bosses are defined on the functional volume but they can be moved with our design
office agreement if it can simplify the manufacture.

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1.12.4. 280V DC/DC Converter :

4 Threaded holes
M6X100

Force
application
point (P):
X= TBD
Y= TBD
Z= TBD

Stiff links

The DC/DC Converter is fixed on four bosses with threaded holes M6X100 with depth 16 mm with a
reception stiffness of 10 8 N/m. The tightening torque is 8 Nm +/- 20%.
Screws will have to be accessible by the screw driving machine with a socket external diameter of 18 mm.
Bosses have to be able to support DC/DC Converter (total mass of 3kg) without damage during all the
vehicle life.

1.12.5. Heating water pump

Force
application (H)
X=TBD
Y=TBD
Z=TBD

Stiff links
The water pump is fixed on two bosses with threaded holes M6X100 with depth 16 mm with a reception
stiffness of 10 8 N/m. The tightening torque is 8Nm +/- 20%.

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Screws will have to be accessible by the screw driving machine with a socket external diameter of 18 mm.
Bosses have to be able to support water pump (total mass of 2kg) without damage during all the vehicle
life.

1.13. FC8 : meet NVH requirements

For NVH performance, the power train have to respect following requirements :
- stiffness of different interfaces (see section corresponding to different interfaces)
- modulation frequency > 20 KHz
- vibration level at engine mount interface (engine speed 4400 rpm, resistant torque 65 Nm at the
transmission shaft) :

X : < 7 m/s²
Y : < 4 m/s²
Z : < 10 m/s²

In order to check NVH performance, the supplier has to give following datas :
- gravity center position
- inertia matrix of the power train at the gravity center
- maximum unbalance level

1.14. FC9 : Withstand to exterior conditions

1.14.1. Temperature

Running underhood temperature : from – 20 °C to 70 °C / Hygrometry : 0  100 %

Storage temperature : from - 40 °C to 85 °C

- Normal temperature work :

Device will be tested under temperature, connected to power supply :

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Continuous operation Tmax

Continuous operation Tmin 1 hours 2 hours 2 hours 2 hours 1 hours

- Storage temperature :
Storage will be tested by applying two cycles of the following type :
16 hours
Storage Tmax

Storage Tmin
16 hours
After test, device will be checked and functional requirements will have to be satisfied as a brand new
product.

- Heat shock :
Temperature will be reached to max temperature during 30 minutes.
After test, device will be checking and functional requirements will have to be satisfied as a brand new
product.

1.14.2. Humidity/condensation :

- Humidity.
Device will be placed in a chamber under a temperature of 40 to 45 °C with 90% to 95% relative humidity
along 100 hours.
After test, all humidity traces will be blown of, device will be checked and functional requirements will
have to be satisfied as a brand new product.

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- Condensation :
Device will be placed in a chamber under a temperature of 40 to 45 °C with 90% to 95% relative humidity
along 24 hours and then placed in a cold chamber under –10°C during 2 hours (changing chamber
operation should last maximum 5 minutes).
Device is then placed in normal condition for at least 2 hours.
After test, all humidity traces will be blown of, device will be checked and functional requirements will
have to be satisfied as a brand new product.

1.14.3. Corrosion

Corrosion prevention : 15 years Safety

12 years Perforation
10 years Breakdowns
5 years Look
3 years Look under body

1.14.4. Projections

Possibility to be subject to projections of :

- Water.
- Gearbox oil.
- Power steering fluid.
- Grease.
- Cooling liquid.
- Battery fluid.
- Brake fluid.
- Windshield liquid
- Gravel (presence or not of a skidplate under engine not yet defined)

1.14.5. Fording and global tightness requirements

Fording characteristic :
Tightness IP 67 below : Z 450mm / Floor  If a “breather” is present, the outlet has to be beyond this Z
limit.
IP 65 above 450 mm /floor.

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450 mm from the

ground (4 passengers)

Front wheel axle

(280.132 mm)

Ground (4 passengers)
0 mm

1.14.6. Breathing

The interface between the Reduction Gear and the Electric Motor will be put to the external atmospheric
pressure via a vent, on the motor housing.
A breathing device have to be include on powertrain on ECM. A gore-tex device could be a technical
solution.

Gore-tex

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1.15. FC10 : Respect regulation

See PD220.0100_AE_e-Powertrain_R08.

1.16. FC11 : Meet crash requirements

The Powertrain must pass the following mechanical shock test levels without any damage or degradation
of performance.

Organic Test :
Test 1 is for Potholes, while test 2 is for shock loads imposed by minor collusion. These test have to be
met by any component, independent of the installation position.
Test 1 as to be realized on the Powertrain, mated to the vehicle interfaces connector and associated
harness, followed by Test 2.

Test 1 Test 2
Acceleration (m/s²) 25 100
Nominal shock duration (ms) 15 11
Nominal shock shape Half sine Half sine
x+ : 10 times x- : 10 times
Number of shock per axis x+ : 3 times x- : 3 times
y+ : 8 times y- : 8 times
(positive and negative) y+ : 2 times y- : 2 times
z+ : 5 times z- : 5 times

Vehicle test :
The different mechanical interfaces have to resist to crash forces that is to say 10 g in x-direction.

Moreover the complete powertrain (including EE devices) must resist without damage to the Danner
shock : 15 km/h

1.17. FC12 : Meet assembly plant constrains

3 rings are required for lifting the powertrain during installation on the jig and for after sale demounting .
These rings have to resist to the weight of the assembled powertrain 80 kg + 20 % during the lift. The
maximum duration of stand by on the rings, for process reason, could be 3 weeks.
Hooks slots dimensions are diam. 18X40 mini.

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 E-POWERTRAIN
AE Project
MECHANICAL STANDARD

3 Lift Rings

The assembled e-pwt is located on the jig with 3 specific areas as described in the following picture.
A locating is on the reduction gear.
To respect isostatisme two others areas on the controller (ECM) have to be defined :
- A slot 12X18 mm
- A plane surface 30x30 mm

Slot 12X18
Hole 12mm
Height 20mm
Diameter
Height 20mm

Plane surface
30X30

Moreover, the power train have to be compatible with assembly constrains like assembly tool dimension
access.

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 E-POWERTRAIN
AE Project
MECHANICAL STANDARD

2. Reliability
This section describe the requirements to be taken into account for the reliability of the power train.
Acceptance criteria for each requirement and test :
- to maintain power trains functionality and performance :variation <5%
- no damage at the interfaces (breakage, cracks…)
- no leakage

In addition, quality and reliability target are detailed on the PD220.0100_AE_e-Powertrain_R08.

2.1. Durability target:

The number of kilometers to be taken into account for the sizing of the car is 200.000 Kms
The targets for the vehicle are :

Life time : 5300 hours in urban mode

1600 hours in peri-urban mode

Use at maximum speed: 70 Hours

Numbers of stop & go : 1 150 000 including 345.000 start at maximum torque
Number of switch on/switch off : 25.000

2.2. Duty cycle

A specific road profile has been created for B°.

It is communicate separately form this mechanical standard and has to be use for durability & reliability
sizing and validation.
See document AE411.TCH.20.004 -C- DUTY-CYCLE for mechanical Parts.

2.3. Static Acceleration

- 1,5g (X and Y direction).

- 3,5g (Z direction)

2.4. Thermal shocks

See section 1.14.1

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 E-POWERTRAIN
AE Project
MECHANICAL STANDARD

2.5. Vibrations resistance

The level of vibrations to be taken into account for the components fixed on the body and on the power
train is :

10

Frequency PSD ((m/s2)2/hz)

PSD ((m/s2)2/hz)

1
5 3
5 10 50 140 350 1000
10 8
50 8
0,1 140 0,8
350 0,8
1000 0,05

0,01
Frequency (Hz)

The component should be running after 8h per axis.

In addition for electronic devices fixed on the powertrain are furthermore submitted to the following
measured vibration spectrum:
Sine sweep from 500 Hz to 3 kHz => acceleration= 90 m/s2
This spectra will be applied on the 3 axis / 75 hours per axis / speed 1 Hz/s.

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