EV TRENDS

HOW THEY ARE DRIVING AMSTED AUTOMOTIVE R&D

07/28/2022
CLUTCHES AND CLUTCHING SYSTEMS FOR OVER 25 YEARS
AMSTED AUTOMOTIVE’S GLOBAL SCALE CONTINUES TO GROW IN NEW APPLICATIONS

Ford 10R140 RWD Mazda SkyActiv FWD GM 6T FWD GM 9T / Ford 8F FWD Honda 10AT Ford 8F57 FWD EV Disconnect

OWC OWC OWC SOWC SOWC SOWC DCC

55+ Million OWCs & 7+ Million SOWCs on the Road System Benefits:
13 Brands - 15 Countries
• Integrated functionality, multiple clutches in one
• Improved propulsion system efficiency
• Decreased packaging space through integration
• Mass reduction through component elimination
• Aluminum utilizations for torque-transferring
components
• High torque density
• System level costs savings
 First Generation Electric Vehicles
eAxle Central Drive
General Architecture
• Single Electric Motor
• Single Speed with Gear Reduction
Gear
eMotor Gear
Main Use Cases Reduction
eMotor Reduction
Box
Box
• Passenger Vehicles
• Transit Buses

Primary Drivers
• Minimize complexity
• Quick to Market
• Keep costs down Differential

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 Second Generation Objectives
Develop Alternate Propulsion Architectures
Maximize Efficiency
• Increase Range
• Reduce Battery Size/Weight
• Reduce Motor Size/Weight

Improve Vehicle Performance

• Increased Torque Capacity

• Improved Handling
• Improved Acceleration at all speeds
• Increase Top Speed

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 Ways to Accomplish Objectives
EV Drivetrains
Alternative Architectures
• Multi-motor propulsion systems
• Multi-axle propulsion systems
• Multi-speed transmissions
eMotor Multi-speed
Transmission
Vehicle Targets Gear
eMotor Reduction
• Commercial Vehicles Box
• High Performance Cars Gear
• Adventure Vehicles eMotor Reduction
Box
• SUV’s and Light Trucks

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 WHAT CAN WE DO TO HELP OPTIMIZE THESE
NEW ARCHITECTURES?

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Development of Multi-Functional Clutch Tech.

Criteria to meet customers needs:

• No Hydraulics
• Minimal Parasitic Losses
• Smooth Shifts
• Quick Actuation Time
• Minimal Packaging
• Provide System Level Efficiency Opportunities

BUILDING BLOCKS
Controllable Multi-function Clutches
• Electrically Controlled
• Clutch and Clutch Brake Architectures
• Multi-Functional Integrated Options
Use Cases
• Disconnects
• Shifting Elements Planer Strut Radial Strut
• Park Lock / Hill Hold
 DEVELOP DISCONNECT SOLUTIONS FOR ANY LOCATION
OPTIONS FROM INPUT (HIGH SPEED, LOW TORQUE) TO OUTPUT (LOW SPEED, HIGH TORQUE)

Motor 1

2 2
a b

6 5 4 3 4 5 6

Gearbox

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New EV AWD Disconnect Solution
EV DISCONNECT PRODUCTION (SOP 2021) – BEV ADVENTURE VEHICLE

Dynamic Controllable Clutch (DCC)

• DCC: Electro-Magnetic actuation
➢ First presented at CTi in 2018
• 1st BEV application – Mechanical Diode system
➢ Disconnect & Lock Mode
• Production launch 2021

Reference: https://www.youtube.com
 New EV AWD Disconnect Solution
DISCONNECT MODE

0/0 DCC
Electro-Magnetic Actuator

Stator
Notch Plate Pocket Plate
Translator
Actuates
Opposing Struts
(Forward / Reverse)

Apply Spring
(Activates Strut)

Return Spring
 New EV AWD Disconnect Solution
LOCK MODE

1/1 DCC
Electro-Magnetic Actuator

Stator
Notch Plate Pocket Plate
Translator
Actuates
X Opposing Struts
X (Forward / Reverse)

X X
Apply Spring
(Activates Strut) X

X Return Spring
Notch Plate Pocket Plate

Return Spring
 Next-Gen EV Disconnect with OWC Functionality
Bicycle Freewheel Analogy → Applied to EV Disconnect
• eMotor Power On
o OWC transmits torque to wheels

• eMotor Power Off

➢ Automatic Disconnect - forward direction
o Coast “Freewheel” - OWC overruns

• eMotor Power On → ramp up to wheel speed Regen

Disconnect
/ Reverse
Re-Connect
➢ Automatic Re-Connect - forward direction
o OWC transmits torque to wheels

• Integrate Controllable OWC for Reverse & Regen With Disconnect

➢ Bi-Directional OWC functionality

o Reverse OWC / Lock Mode
o Engage & disengage as needed
Next-Gen EV Disconnect with OWC Functionality
BUILDING BLOCKS – EVOLUTION OF CLUTCH EXPERIENCE

One-Way-Clutch OWC + Controllable Lock Mode Disconnect + Lock Mode

Mechanical Diode OWC Grounded Electro-Mech Actuation Dynamic Controllable Actuation (DCC)
AT 1-2 Gear Shift – SOP 1997 AT 1-2 Gear Shift + Reverse - SOP 2016 EV AWD Disconnect - SOP 2021

Controllable Bi-Directional OWC

Forward OWC + Controllable Reverse OWC
Next-Gen EV Disconnect with OWC Functionality
AWD DISCONNECT WITH INTEGRATED & BI-DIRECTIONAL OWC

Controllable OWC Passive OWC

(Reverse / Regen) (Forward)

Controllable OWC Passive OWC

(Reverse / Regen) (Forward)

Input

from
Motor

Driven Plate Driver Plate Driven Plate

(Reverse /Regen) (Forward)
 MULTI-SPEED SHIFTING VIA ELECTROMECHANICAL CLUTCHES
COAXIAL AND PARALLEL AXIS ARCHITECTURES USING MEANS TECHNOLOGY
Multi-speed Coaxial Transmission Multi-Speed Parallel Axis Transmission

• Holds torque in 1st gear,

Reverse, & Regen
• Overruns in 2nd Gear

Vehicle-Level Benefits
• Uninterrupted torque delivery during 1-2 upshift Vehicle-Level Benefits
via passive OWC
• One clutch control for 1-2 upshift • Uninterrupted torque delivery when incorporating
• Smooth, consistent 1-2 upshifts throughout optional OWC functionality
transmission life • Low parasitic losses – no friction clutches
• Increased system efficiency • No power consumption in state – bistable actuators
• Compact packaging • Fast shift times – 20 ms clutch response time
• Proven functionality (8+ Million CMDs in field) • Efficient packaging with electric actuation
15 • High-speed shifting capability
Electric Park Lock / Hill Hold
ENABLED BY CMD TECHNOLOGY
Park-Lock system solutions
for BEV electric drivetrains

**Can be configured to be radial or planar

Vehicle-Level Benefits
Means eSOWC - enables • Fast engagement time – 20 to 40 ms
all modes in one device
• Low energy consumption per state
change – 10 – 25 joules
• No energy consumption in state –
clutches magnetically latch
• Added hill hold functionality possible
with four modes of operation
• Functional safety: ratcheting fail safe,
position sensors at locking elements
 Differential With
Integrated Disconnect

Co-axial
Transmission
Shifting Element

Park Lock /
Hill Hold
Parallel Axis
Transmission
Shifting Element

Class 8 Wheel End Disconnect

Closing Comments
Customer driven R&D and Advanced Engineering Projects
• 100% of new opportunities are in Electric Vehicle applications
➢ 50% are Disconnects
➢ 40% are clutches for multi-speed shifting systems (transmissions)
• Our number of active projects has increased 85% over the last 6 months
• Current largest customer pull is for disconnects and shifting elements that have overrunning
functionality
• Critical customer needs: Minimal parasitic losses (no hydraulics), Smooth and Quick shift
transitions, Small packaging requirements, Avoid complex calibration needs
• Production or prototype electrified clutches being used in EV’s include:
➢ Commercial Vehicles
➢ Aerospace
➢ Light Truck
➢ Passenger Cars
➢ (Soon to deliver prototypes for Agricultural application)
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THANK YOU !