The automotive industry is undergoing a significant shift as major manufacturers plan for a future dominated by electric vehicles (EVs). This transition involves more than just a change in technology; it also has cultural implications and requires a new set of skills. Audi’s powertrain plant in Gyor, Hungary, is at the forefront of this transformation. As the largest powertrain plant in the world, it is responsible for producing electric drivetrains for Audi’s new Premium Platform Electric (PPE) developed in collaboration with Porsche.
The shift from traditional powertrain manufacturing to electric motors is evident at Audi’s facility in Gyor. Instead of casting and machining engine blocks, the focus is now on producing the stators and rotors of electric motors. While the end result may have fewer moving parts, there are still many components that need to be assembled. The use of automatic bending machines to create U-shaped ‘hairpin’ windings has replaced the continuous lengths of wire used in traditional windings. Each stator comprises 140m of copper wire joined into continuous lengths with 235 laser welds. The transition to electric powertrains also allows for more efficient assembly processes, with fewer bolted fasteners and increased use of robots.
One of the advantages of electric powertrains is their modularity. By simply adjusting the length of the motors, torque output for different vehicles can be easily changed. The transmission systems in EVs are also simpler compared to internal combustion engines (ICEs), allowing for variations in torque at the wheels and maximum speed by adjusting gear ratios. This modular design and simplified transmission contribute to the overall efficiency and performance of EVs.
Contrary to popular belief, EV technology has evolved rapidly in recent years. Audi’s new PPE motors take up 30% less space and are 20% lighter than earlier models. The hairpin winding technique used in these motors allows for a higher ‘fill factor’ of 60%, compared to 45% in conventional windings. This means that more windings can fit in the same space, resulting in increased torque from motors of the same size. Additionally, the use of oil-cooled rotors has improved efficiency by reducing losses caused by drag by 50%. Overall, the power-to-weight ratio for PPE motors is now 60% higher than Audi’s first-generation electric motors.
While electric motors may not have the same level of complexity and sound as internal combustion engines, they are far from dull when it comes to performance and efficiency. The advancements in EV technology showcased at Audi’s Gyor plant demonstrate the industry’s commitment to embracing the future of electric mobility. As manufacturers continue to invest in research and development, we can expect even more innovative and exciting developments in the world of electric vehicles.