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! 

Noise, vibration and harshness (NVH) performance and optimization for EVs is currently a focus area for many in the industry. This article highlights NVH challenges due to the complex interactions between electric powertrain components as well as DSD’s motor modeling and simulation expertise to help better predict NVH performance and any potential issues.

Read more here: https://www.emobility-engineering.com/system-level-approach-to-nvh-models/

Publication: E-Mobility Engineering

Author: Nick Flaherty

In the hunt for sustainable, carbon neutral mobility, the world of electrification is brimming with possibilities. However, navigating uncharted territory can be challenging. This article reviews the need for a knowledgeable partner that excels in full-system integration, the advantage of simulations and the benefits of sustainable materials.

Read more here: https://ehv.mydigitalpublication.co.uk/july-2023?m=63184&i=797327&p=2&ver=html5

Publication: Electric & Hybrid Vehicle Technology International

Drive System Design (DSD), a global specialist in the engineering and development of electrified propulsion and actuation systems, is projecting a significant increase in its off-highway work this year, from 5% in 2021 to 35%.

This growth is in line with DSD’s strategic priority to heighten its commitment to meeting the needs of the off-highway sector. In the third quarter of 2022 in Europe, the economic sectors responsible for most greenhouse gas emissions were manufacturing (23 %), electricity, gas supply (21 %), households and agriculture (both 14 %), followed by transportation and storage (13 %)*.

In-line with its expansion into the off-highway sector, DSD is making its debut at iVT Expo. iVT is a global showcase of the components, services and technologies that go into making the next generation of industrial vehicles and improving the associated development, manufacturing and testing processes.

At the Expo, held in Cologne, Germany (28 – 29 June), Elena Belenguer, Engineer at DSD will take to the stage to deliver a technical presentation discussing how cross platform strategies can improve efficiency when moving towards electrification for off-highway vehicles. The talk will give insight into existing electrification challenges within industry, in addition to DSD’s approach to de-risking, reducing cost and development time in electrified powertrain design. In addition, DSD experts will also be on stand 2056, to discuss the application of its propulsion and actuation expertise in the off-highway space.

Lee Sykes, Commercial Director at DSD, commented: “With the global off-highway electric vehicle market set to grow at a 14.1% CAGR from 2023 to 2030, DSD is proud to leverage its core strength in complex electrification engineering to serve the off-highway sector. With our unique combination of toolsets and expertise, we are committed to being at the forefront of addressing the sustainability challenge in the industry and enabling our customers to realise the benefits of embracing electrification.

“We are excited to make our debut at iVT Expo and showcase our expertise in heavy duty transmission design, motor and power electronics development as well as the critical control systems that bring these to life,  enabling us to provide electrified solutions to this sector.”

Transitioning to electrification opens up a lot of possibilities with many new design decisions to be made, including whether or not to replace fluid power system components. Jason Schneider, chief engineer of Electrified Powertrain at DSD, examines the impact of electrification on hydraulics and pneumatic components and explains key points to consider during the design process.

Read more here: https://www.powermotiontech.com/hydraulics/article/21266050/qa-design-considerations-for-electrification-and-fluid-power

Publication: Power & Motion

Author: Sara Jensen

While there are certainly barriers and challenges to overcome, DSD’s Ben Chiswick addresses how an electric and autonomous future in the defense sector will greatly improve the efficiency and effectiveness of military operations, while also substantially reducing the environmental footprint, fully burdened cost of fuel and risk to human life. To fully maximize the benefits that autonomy and electrification can bring, a completely new vehicle architecture is required, making room to re-envision what these vehicles could look like, what technology can be integrated and how much more power can be squeezed from having more design freedom.

Read more here: https://www.nxtbook.com/smg/techbriefs/23ADT05/index.php#/p/6

Publication: Aerospace & Defense Technology

Author: Ben Chiswick

OEM Off-Highway previews what’s expected at CONEXPO 2023, with an emphasis on what industry influencers are looking forward to being on the show floor and where the industry is headed. Ben Chiswick, director of Engineering Business Development at DSD, was among those commenting, highlighting the shift in traditional mindsets to meet both industry regulations and the demand for electrified solutions.

Read more here. https://www.oemoffhighway.com/trends/article/22684712/what-to-look-forward-to-during-conexpo

Publication: OEM Off-Highway

Author: Lori Ditoro

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.