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.”

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

To speak to one of our experts on the topic, get in touch here

This year marks a significant milestone for Drive System Design (DSD) as we celebrate the 10th anniversary of our US business. A decade ago, we embarked on a journey to cultivate a community of exceptional engineers dedicated to inspiring and challenging the rapidly evolving mobility industry. 

Since our inception, DSD has experienced remarkable growth and success. Today, our teams in the US and UK comprise over 150 experts, united by a shared passion for engineering excellence and innovation. Together, we have forged a reputation for delivering cutting-edge solutions in electrified propulsion systems and associated technologies. 

As we reflect on the past decade, we are immensely grateful to our talented team whose dedication and expertise have been instrumental in shaping DSD into what it is today. Their commitment to excellence has propelled us forward, enabling us to establish ourselves as a trusted partner for automotive, off-highway, commercial vehicle, aerospace, and defence OEMs, Tier-1 suppliers, and industry research bodies worldwide. 

We pride ourselves on our turnkey capabilities and unmatched expertise and have built a team in the US that embodies that. We’ve grown to now be collaborating across a diverse array of sectors and become a trusted technical partner for many of our clients, without whom we wouldn’t be where we are today, and on the growth path we’re on for the future. 

As we commemorate this milestone, we extend a heartfelt thank you to our team, clients, and partners for their unwavering support and collaboration. After our acquisition by Hinduja Tech in 2022, our future holds even greater potential. Together, we look forward to the next decade and beyond, as we continue to drive innovation, shape the future of mobility, and redefine what’s possible in the world of engineering. 

Here’s to the next decade of excellence, achievement, and innovation at DSD! 

Aviation companies are looking for alternative energy solutions, including electric engines that run on hydrogen. Lee Sykes, commercial director at DSD, weighs in on the potential for hydrogen applications and on how this fuel source could have a positive impact on cost.

Read more here: https://www.verdict.co.uk/zeroavia-promises-commercial-carbon-free-flights-within-two-years/

Publication: Verdict

Author: Simone Bateson

It’s truly an exciting and highly opportunistic time for engineers, as we build out an entirely new energy ecosystem on a global scale, full of uncharted territory and exhilarating challenges.

While much of the obvious focus is on what will be made, the engineering community is focused on how it will be made. The mix of traditional engineering and software integration has caused nearly every manufacturer in the EV space to rethink how to build their development teams to get their products to market quickly, reliably and cost effectively.

At the recent SAE COMVEC™ a panel about the “war for talent” struck a chord with our team about the challenges we face, where we find ourselves and where we’re going as engineers. With an estimated $1.2 trillion being invested in EV development through 2030, the type of engineering necessary to build not only the vehicles themselves, but the technology and infrastructure to support them is requiring an entirely new type of thinking and collaboration – along with a significant amount of hiring. As we continue to see investments taking place in our backyard, such as CNH Industrial recently announcing that it has opened a new technical centre in metro Detroit to support its growing innovations in electrification, the competition for talent locally surges.

DSD has a strong history of developing powertrain technology and collaborating with OEM partners to supplement and reinforce their internal teams. Our expertise lies in having experienced and forward-thinking engineers who go into a project with an open mind to find the right solution for a specific application. With years of expertise in the segment, our company has continued to evolve our EV propulsion capabilities and excels at developing motors and controls for the automotive, aviation, commercial vehicle, off-highway and defence industries.

The COMVEC panel drew attention to the obvious need for expanding engineering talent, training and hiring, but also of having partners in place to supplement manufacturers where needed.

Further, a recent Automotive News storey cited the 35% increase in STEM-related jobs during the past 20 years, which is expected to increase even further during the next decade. The pressing question is whether there will be enough incoming talent to meet the demands of the industry. There are programmes locally in place to help kerb the issue, for example, the Detroit Regional Chamber Foundation and MICHauto recently were awarded a $2 million grant to support the growth and development of high-tech talent in Michigan, spanning automotive, mobility and technology sectors, but some of these measures will take a significant amount of time.

With the substantial investment in the move to EVs, our customers must determine if they should build or expand their internal product development teams, work with trusted partners or both. It’s an interesting position for companies like DSD. The company can be hired to supplement internal programmes or be contracted for turnkey development.

DSD routinely supports clients with our trusted engineering team members – having them work on-site with the customer team. This can be extremely beneficial when projects come in and there just isn’t time to find the perfect candidate for the job. And since there are more opportunities than there are engineers suited for positions, finding the right hire and having them commit can take time – something that manufacturers don’t always have.

Of course, a key concern with outsourcing projects through contractors can be that once the project is over, the knowledge behind that project goes with it. In an effort to collaborate at the deepest level and facilitate the creation of rapid and effective teams, our clients take the IP with them upon a project’s completion.

DSD’s advantage lies in the fact that we understand what our customers need and fully realise that what they need today, may change drastically in 12 months. Further, the company has the flexibility, capability, and expertise to work in multiple segments and on multiple projects across multiple regions at the same time. This allows us to pivot easily and ramp teams up or down to align with client needs.

We understand the difficulties of deciding whether or not to staff up or collaborate with companies like DSD to supplement an existing workforce, and we are prepared to help our customers navigate that decision, helping them minimise the risk and maximise the ROI.

Drive System Design (DSD), a company specialising in the rapid engineering and development of electrified propulsion systems and Alvier Mechatronics, an engineering service company with special competence in advanced materials and production methods for sustainable, high-volume applications, are joining forces to provide the mobility industry with engineering services to support sustainable electrified propulsion solutions across automotive, commercial vehicle, off-highway, marine and aerospace applications.

The two companies signed a joint operating agreement to combine DSD’s expertise in full electrified propulsion system design encompassing simulation, prototyping and validation, with Alvier Mechatronics’ industry-leading capabilities in powder metallurgy and electromagnetic design. This collaboration will unlock significant improvements in the development of electrified systems, and bring innovative turnkey solutions to the industry, including:

• Speed-to-market increase by combining metallurgical and electromagnetic phases of development and reduced prototype lead-time.
• Sustainability improvements in the use of CO2, resulting in an overall reduction during the development process, to complement both companies’ ability to reduce CO2 production during system operation.
• Expertise from the combined experience and resources of Höganäs AB, DSD and Alvier Mechatronics.

“This collaboration will capitalise on the combined skills and capabilities of each company to serve our new and existing customers in exciting ways,” said Daniel Hervén, CEO, Alvier Mechatronics.

“Working with Alvier Mechatronics is a great opportunity for DSD to diversify its contribution to the advancement of sustainable electrified propulsion across an array of critical industries,” said Mark Findlay, managing director, DSD. “It is a company with trusted capability in the industry, and we look forward to pushing the boundaries of sustainable electrification.”

About Alvier Mechatronics:

Alvier Mechatronics is part of the Höganäs Group, market leader in metal powder. As a start-up company founded in 2018 with the ambition to develop knowledge driven eDrive solutions Alvier Mechatronics offers companies a fast track to build high-performance and integrated eDrive solutions through advanced engineering services. From concept ideation through design, simulation, validation and prototyping to building a-samples, we use a systematic approach to obtain lower weight and a reduced number of parts while increasing overall efficiency.

For more information, visit alviermechatronics.com.

Drive System Design (DSD), a company specialising in the rapid engineering and development of electrified propulsion systems and associated technologies, has developed a new method and strategic plan to better support clients in designing and developing electric motors and inverters that best fit their needs.

DSD has observed that many motor and inverter manufacturers, as well as system integrators, often take their electrification development programmes directly to a dynamometer (dyno) test cell, only to uncover critical issues that need to be overcome, which can stop the programme in its tracks. With this seemingly direct approach, months are added to the project timelines in order to find and fix unforeseen integration issues.

To help save its customers months of time and tens of thousands of dollars, while ensuring a more robust, reliable concept before ever touching a dyno test cell, DSD has created a new Motor Control Development Method consisting of four key phases that it will now implement for most electric motor and inverter development projects.

“There is immense benefit in minimising project risk by following our four-phase approach. Too often, a push to be first-to-market ends up incurring more cost and time,” said Jon Brentnall, president, Drive System Design. “Ultimately, this approach will enable our customers to be first-time capable, meaning they will be set up for a successful pairing of the inverter and motor once the product reaches the dyno test cell. This will speed up final validation and significantly reduce the risk of needing extra hardware iterations, saving our customers both time and money while delivering a more high-quality product.”

Below is a look at DSD’s four-phase approach, with many companies currently skipping from Phase 1 to Phase 4:

• Phase 1 – Concept evaluation and design with advanced co-simulation. During this phase, control algorithms, finite element analysis (FEA) motor models and the power electronics model are designed and developed. A closed loop advanced co-simulation of the entire system will then be performed. By driving the system model with more representative control signals rather than simpler idealised inputs, early-stage identification of electromagnetic challenges along with accurate early-stage data for larger system analysis activities like noise, vibration and harshness (NVH), can be achieved.
• Phase 2 – Detailed design and validation with Control Hardware-in-the-Loop (C-HIL). DSD will utilise inverter control board hardware with deployed software and a real-time simulation of the motor model. The C-HIL hardware emulates motor behaviour and sensor feedback such that a large proportion of the software and low voltage hardware validation can be performed. This phase allows for development and validation of safety monitoring and fault handling without risking hardware failures. Software development time is reduced for subsequent phases through bug fixing at this stage.
• Phase 3 – Component level testing with Power Hardware-in-the-Loop (P-HIL). At this stage, a large proportion of the inverter validation will take place by running full power through the inverter with deployed software and utilising a battery and a high voltage motor emulator. The motor is modelled but real current and power is being pushed through real inverter hardware to validate its power stage and control. When a novel motor design is in the manufacturing stage, DSD can leverage its open platform inverter, to quickly and efficiently develop, calibrate and validate the motor controls for that application in this phase of testing.
• Phase 4 – System level testing and validation on a dyno test cell. The motor will enter the dyno test cell at this stage as a final system validation and characterisation utilising inverter and motor hardware as well as the battery emulator. Going through the previous stages ensures this phase will be as short, cost effective and efficient as possible.

As an initial investment to fulfil its new motor development strategy, DSD has acquired a C-HIL rig, which will be housed at its technical centre in Farmington Hills, Michigan. Additionally, DSD will be partnering with the Auburn Hills-based rig supplier to have access to their P-HIL rig and motor emulator, with plans to invest in one of its own next year.

“Real-world issues can now be predicted or reproduced and solved prior to – or in parallel with – dyno or test cell work,” said Brentnall. “This new approach and equipment will further advance DSD’s turnkey capability of delivering motor controls and electrification across a range of markets.”

Through DSD’s method, customers will now be able to better optimise their time, as a large proportion of the inverter software and hardware can be developed and validated through Phase 2 and 3 while the motor hardware is being made. Further, the method is adaptable for various vehicle types, including automotive, trucking, off-highway, defence and aerospace.

With the immense value of taking a more comprehensive approach to motor and inverter design and development like DSD’s, the company predicts that most companies tackling similar projects, including key competitors, will adopt a similar approach in the next five to 10 years.

DSD has been officially presented with its Queen’s Award for Enterprise in International Trade

Drive System Design (DSD) has been officially presented with its 2020 Queen’s Awards for Enterprise in International Trade following delays due to the pandemic. The award recognises the sustained growth of the company, which over the three years prior to the pandemic achieved substantial year-on-year growth with overseas sales rising 155%.

“We are delighted to be presented with such a prestigious award and I am hugely proud of everybody at the company, without them, this would not be possible,” said Mark Findlay, Managing Director of Drive System Design. “The award goes someway to reflect the amazing achievements of our team, who are developing state-of-the-art electric propulsion technologies. They are directly contributing to a greener more sustainable future, right here in Warwickshire.”

Tim Cox, His Majesty’s Lord Lieutenant of Warwickshire, and the Royal Family’s representative for the area said, “Warwickshire is at the heart of the automotive industry in the UK and Drive System Design is an excellent example of top British engineering in the area. The Queen’s Awards are the highest honours for a UK business and bring with them a great level of credibility and prestige. Drive System Design is thoroughly deserving of this accolade.”

The Queen’s Awards for Enterprise, the most prestigious business award in the UK, was established in 1965. The International Trade category recognises outstanding growth in overseas earnings and rewards companies for demonstrating steep year-on-year growth internationally. The Awards celebrate the success of exciting and innovative businesses that are leading the way with pioneering products or services.

DSD is at the leading edge of British engineering, developing next-generation electrified powertrains for the world’s leading vehicle manufacturers and global Tier 1 suppliers. The company employs 80 people at its headquarters in Leamington Spa, which has grown by more than 10% in the last 12 months alone. Internationally it has 120 employees, with a technical centre in North America and locations in Asia and Australia.

Drive System Design (DSD), a company specializing in the rapid engineering and development of electrified propulsion systems and associated technologies, has added several new members to its team following significant electrification business growth.

Among the six new team members at its Farmington Hills, Michigan, facility are individuals who have strong backgrounds at Tier One suppliers and original-equipment manufacturers. Specialties range from motor controls to transmission systems, e-axles and more.

“There has been a tremendous amount of growth, both in personnel and diversification of business, taking place at Drive System Design and we’re excited to add these exceptionally talented engineering experts to our team,” said Jon Brentnall, President at Drive System Design. “Collectively, their impressive backgrounds will help us further broaden and enhance our electrified propulsion expertise as we continue to tackle a range of electrification initiatives spanning automotive, defense, aerospace, commercial vehicle and marine sectors.”

With the addition of the new team members, DSD now has 35 employees at its Farmington Hills facility, with expectations of adding another half a dozen team members by the end of 2022.

Information about each of the new team members can be found below.

AK Arafat, Principal Controls Engineer

As Principal Controls Engineer, AK Arafat will be responsible for executing motor control projects and helping shape DSD’s development of motor design, analysis and test processes through continual R&D investment. Most recently a Technical Specialist in power electronics at Cummins, where he worked for three years, AK Arafat brings a breadth of experience in high power electric power conversion, motor controls, inverter software creation and optimization, and electric machines to DSD. He has invented 17 technologies and published 29 research papers on motors, controls and diagnostics throughout his career. Additionally, he has led cross-functional and global teams in a variety of initiatives, including investigating existing motor drive functionalities and failure modes. He has also tested, calibrated and validated multiple electric drive units for heavy-duty EV commercial applications.

Arafat earned a master’s degree in electric engineering from the University of Akron, Ohio, and a bachelor’s degree in electrical and electronic engineering from the Bangladesh University of Engineering and Technology.

Taechung “TC” Kim, Chief Technical Specialist

Joining DSD as a Chief Technical Specialist, Taechung “TC” Kim, will be responsible for leading full-scale electric drive unit design and analysis projects, while mentoring the team around him. With a strong engineering background, Kim is able to draw from extensive experience with e-axles and simulation for NVH and transmissions. Prior to joining DSD, Kim worked as a Lead Transmission Engineer at Wrightspeed Powertrain Inc. He also previously worked as a Senior Principal Engineer of model-based design for Toyota Motor North America in Ann Arbor, Michigan, and Senior Manager and Senior Research Engineer of powertrain CAE for Hyundai and Kia Motors in Korea. During his career he was the Design Lead for an EV commercial vehicle e-axle with range extender options project, in which he developed a high ratio four-speed co-axial transmission for durability, NVH and controls for a Class 7 and 8 vehicles.

Kim earned a Ph.D. in mechanical engineering from Ohio State University, a master’s degree in mechanical engineering from Lehigh University in Bethlehem, Pennsylvania, and a bachelor’s degree in mechanical engineering from the State University of New York.

Andrew Jamieson, Principal Engineer

Andrew Jamieson has been hired on as a Principal Engineer. He brings more than 15 years of experience as a Design Engineer, Senior Design Engineer and most recently Technical Specialist at MAHLE Powertrain. Jamieson has had a vast amount of experience with engines and mechanical systems from automotive to marine to defense applications throughout his career. He has designed and developed a novel crank train arrangement for a powerboat engine and led a team designing the housing assembly for a military cross-drive transmission, among other projects.

He earned a master’s degree in automotive product engineering from Cranfield University in the U.K. and a bachelor’s degree in mechanical engineering from Napier University in the U.K.

Mario Escareno, Senior Control Engineer

As a Senior Control Engineer, Mario Escareno will work on an array of control software development, demonstrator vehicle calibration and system simulation projects at DSD. Most recently, Escareno served as an Electrified Controls Systems engineer for Ford Motor Company, where he worked for nearly a decade. During the course of his career, Escareno has developed control systems for electric and hybrid vehicle high level functions, managed controls integration and program management for more than 24 programs, and worked on various functional safety and failure protection assignments.

Escareno earned a professional certification in architecture and systems engineering from the Massachusetts Institute of Technology as well as a master’s degree in business administration from TecMilenio University and a bachelor’s degree in aeronautical engineering from the National Polytechnique Institute in Mexico City.

David Loki, Transmission Engineer

David Loki is joining DSD as a Transmission Engineer, following a Product Engineering role for eAxle Pursuit at Linamar. Previously Loki has worked to design and develop a differential disconnect mechanism for use in AWD electric vehicle applications and as an analyst and build coordinator for a dual motor, hybrid multi-speed transmission in a commercial vehicle application.

Loki earned a bachelor’s degree in mechanical engineering from University of California, Davis.

Matt Emmerson, Transmission Engineer

Coming to DSD with a substantial background in testing and development, Matt Emmerson will now take on the role of Transmission Engineer. Most recently he worked as an 8-speed Transmission Development Engineer for GM. Emmerson brings a breadth of experience in design and analysis engineering as well as testing. Additionally, he has created and coded many universal advanced data post-processing development tools as well as several automatic transmission tests and tools that supported advanced transmission functionality and controls.

Emmerson earned a master’s degree in industrial & systems engineering from the University of Michigan and a bachelor’s degree in mechanical engineering from the New Jersey Institute of Technology.