Drive System Design (DSD), a leading engineering and mobility consultancy, has expanded its capabilities by acquiring the assets of Midlands-based engineering consultancy Lyra Electronics. This strategic move significantly enhances DSD’s Electrified Powertrain (EP) function, a core offering for its customers.

Renowned for its expertise in electrified driveline and transmission systems, DSD has been at the forefront of the electric vehicle sector since 2010. The acquisition enables DSD to offer increased capability in the area of power conversion, including the development of DC-DC converters, onboard chargers and PDUs, as well as broadening its X-in-1 design capabilities as full system developers. OEMs and manufacturers in automotive, aerospace, defence, commercial vehicles, off-highway, and marine sectors will benefit from these advanced skills and integrated solutions.

This move aligns with DSD’s commitment to engineering excellence and innovation. The acquisition follows DSD’s recent showcases of its technological expertise at global events such as IAA Transportation 2024 in Germany, CTI Symposium 2024 in the US and JSAE in Japan.

Jason Allen, Managing Director at DSD, commented: “Our people are our biggest asset at DSD, unmatched in their technical expertise and commitment to engineering excellence and innovation. Expanding our Electrified Propulsion offering is a significant step in our ability to deliver fully integrated systems to our customers throughout the world.”

Drive System Design (DSD), a leading engineering consultancy and a key subsidiary of Hinduja Tech acquired in December 2022, is poised to showcase its latest advancements in electrified propulsion systems at IAA Transportation 2024, to be held in Hannover, Germany, from September 17-22, 2024. 

As the premier partner for cutting-edge mobility solutions, Hinduja Tech (HT) delivers exceptional value across all vehicle platforms, including the burgeoning realm of new energy vehicles. Hinduja Tech’s mastery of frugal engineering and risk mitigation ensures that the product development journey is cost-effective, efficient, and steadfastly reliable. From concept to series production, HT’s expertise guarantees success. The distinctive global delivery model seamlessly integrates deep onshore domain and technical expertise with near-shore and offshore engineering expertise, ensuring rapid time-to-market and value-for-money solutions with an unwavering commitment to product quality.

Together, HT and DSD are committed to playing a pivotal role in the global transition towards a sustainable transportation future by providing innovative engineering solutions for all vehicles, including electric, hybrid, and conventional powertrains.

A legacy of excellence in electrified propulsion

Drive System Design (DSD) is a global engineering consultancy with a rich legacy in designing drivelines and transmission systems for conventional internal combustion engine (ICE) vehicles. Building on this foundation, DSD has been at the forefront of the electric vehicle revolution since 2010, specialising in the rapid engineering and development of electrified propulsion systems and associated technologies. With decades of experience and a team of award-winning engineers, DSD offers unparalleled expertise trusted by leading OEMs, Tier-1 suppliers, and research institutions across the automotive, commercial vehicle, aerospace, off-highway, and defence sectors. As a one-stop shop for propulsion systems engineering, DSD operates technical centres in North America and the UK, with commercial centres in South Korea, Japan, and India, providing its clients a global reach.

Unmatched expertise across the electrification spectrum

DSD’s core competencies lie in systems integration, system attribute optimization, performance enhancement, and development testing. By leveraging this unique combination of expertise and state-of-the-art testing equipment, DSD delivers innovative and optimised solutions across the entire spectrum.

Driving innovation at IAA Transportation 2024

At IAA Transportation 2024, DSD will be showcasing its cutting-edge solutions at its booth:

• PHEV-DCT Transmission is a marquee project highlighting DSD’s ability to optimise PHEV performance by developing a new transmission for a leading European OEM. In addition to maximising fuel efficiency with an ultra-wide ratio dual-clutch architecture, the premium driving experience was maintained, all managed by DSD’s Infinite Control Software platform.

• Sustainability enhancement with powder metallurgy: Drive System Design (DSD), with its unique engineering expertise, brings material innovation to industry production, thereby ensuring durability, reliability, and efficiency requirements. By using powder metal on high-volume products, one can achieve cost savings of ~15% and reduce the carbon footprint of the said part by ~40%. Additionally, DSD is driving the adoption of soft magnetic compounds in motor design. This innovative material offers a compelling combination of superior performance and price stability, setting a new standard in the industry.

• Lubrication testing of e-Axle transmission: DSD, through its one-of-a-kind validation process, wherein physical validation was used in combination with virtual validation via CAE tools, was able to left-shift the design program for a leading automotive manufacturer. The design performance was evaluated for all possible driving scenarios to ensure efficiency and durability.

• Open Platform Inverter (OPI) SiC: This is a powerful and versatile inverter hardware and open software platform for motor components and motor control IP development.

The UK Head of Control Systems, Pedro Zabala, will be in attendance and available to discuss DSD’s Open Platform Inverter and their Infinite Control Software platform, which has been used in aerospace, mining vehicles, and class 8 trucks.

“The acquisition of DSD in 2022 marked a significant milestone for Hinduja Tech,” said Mr. Shankar V., EMEA Regional Head of Hinduja Tech.

“DSD’s expertise in powertrain systems perfectly complements our existing capabilities, and their presence in the EMEA region has been instrumental in driving our growth here. Together, we are well-positioned to lead the global shift towards a cleaner transportation landscape.” 

“As a leading force in drivetrain systems, attributes optimization, and performance enhancement of propulsion system development, DSD is committed to collaborating with industry leaders to accelerate their efficiency improvement programs,” added Mr. Mark Findlay, CEO of Drive System Design. 

“We invite journalists and industry professionals to visit our booth at Hall H23, stand C32 at IAA Transportation 2024 to explore how DSD’s innovative engineering solutions can help them achieve their clean transportation goals.”

Lee Rogers, Principal Engineer – Electrified Propulsion, at Drive System Design (DSD), outlines how powder metal gears can support EV production and how DSD’s work with industry-leading materials specialist Alvier has supported the development.

Manufacturers throughout the transport industry are aware that they now need to be placing significant investment in cheaper, cleaner, lower carbon technologies to support net-zero goals.

When considering our customers in the European Union (EU) in particular, we know that increasing legislation around lower carbon footprints is placing even more pressure on them to find sustainable electrification solutions.

What are we doing?

In collaboration with Alvier, specialists in advanced materials and production methods for sustainable high-volume applications, we are integrating powder metal gears into an automotive EDU demonstrator. This near-net-shape design eliminates a significant amount of material waste with a minimal difference in package/weight when compared to traditional forged gears.

These gears can be used in a range of vehicle sectors from automotive to off-highway and will enable significant cost savings at high enough volumes. The major reduction in CO₂ is also a major bonus as Electric Vehicle (EV) production volumes rapidly increase.

We’re not stopping there. We’re supporting our customers by providing guidance on how to implement the gears into their specific systems, to ensure their needs are met whether they’re manufacturing cars, trucks or tractors.

How did we do it?

Our partnership with Alvier enabled us to replace some traditionally manufactured gears in an EDU with a powder metal counterpart.

• Identifying the right candidate

Utilising Alvier’s experience in powder metallurgy, which is the process used to develop powder metal gears, we built an understanding of the manufacturing constraints that would apply in volume production. When combined with DSD’s transmission engineering expertise we were able to identify the right component candidates to be replaced with powder metal gears. This led to us identifying the gear wheels as good candidates.

• Understanding the material performance

The next step was to understand the differences in material properties. The strength and noise performance of the gears must be equal to or better than a traditional solution to be competitive. DSD performed modal characterisation of both forged and powder metal gears to understand their baseline differences in terms of frequency and damping.

Similarly, using Alvier’s understanding of the powder metal fatigue performance, DSD was able to size the gears to meet the required contact and bending safety factors.

• Predicting performance

Using the characterised material data we were able to simulate the NVH and strength performance of the gear design against the original requirements. We predicted that these would have similar performance to the existing forged gear wheels. This meant me were able to move onto the prototype stage with confidence that the gears would work successfully.

• Finding the break-even point

Before entering the production phase, we used our ePOP tool and costing experience to model the breakeven point of the powder metal gears against the existing forged gears, to understand what volumes would be economically successful.

What’s the result?

The collaborative effort with Alvier throughout the process means we now have the confidence to take this powder metal gear design into prototype hardware. The thorough understanding of the manufacturing constraints, material properties and resulting performance means DSD is primed to help OEMs and Tier suppliers integrate this new technology into their products successfully.

Why DSD?

Successfully integrating new technologies such as powder metal gears to achieve lower cost and carbon footprint requires a collaborative approach that involves both manufacturing and design expertise.

High-frequency abnormal noises continue to pose challenges to engineers when developing electric and hybrid vehicles.

Jordan Craven, our Senior Engineer, and Rob Hoffman, US Director of Development and Test, recently spoke to Automotive Testing, a key publication covering automotive evaluation, diving into the increased interactions caused by the complex electronic, electromagnetic and mechanical subsystems in highly integrated electrified powertrains.

Jordan discussed the importance of understanding noise, vibration and harshness (NVH) considerations and having effective simulation capabilities to identify issues before they emerge in prototype hardware. Rob shed light on the importance of having the right development and test methodologies in place to support the NVH development of modern powertrains.

You can read the whole article here: https://automotivetesting.mydigitalpublication.com/publication/?m=71151&i=816648&p=26&ver=html5

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