A FULLY INTEGRATED APPROACH TO DRIVETRAIN DEVELOPMENT
Dana's Spicer Electrified with TM4 portfolio of fully integrated electro-mechanical propulsion systems feature gearboxes, electric motors, inverters, and thermal-management technologies
US-based drivetrain technology company Dana has unveiled its comprehensive Spicer Electrified with TM4 portfolio, including fully integrated electro-mechanical propulsion systems featuring gearboxes, electric motors, inverters, and thermal-management technologies.
Ranging from complete systems and modular solutions to individual subsystem components, Dana offers support in developing series and parallel hybrid configurations up to full battery-electric vehicles in the light vehicle, commercialvehicle, and off-highway markets.
With the recent acquisition of TM4, Dana’s electrification capabilities now include in-house design and manufacturing for electric motors, power inverters, and control systems. Combined with Dana’s existing core expertise in driveline, sealing, and thermal management, the company employs a systemsfocused approach to e-propulsion, guiding electric and hybrid vehicle development for enhanced performance, packaging optimization, and reduced system weight.
Commercial vehicle manufacturer Karsan has incorporated Dana’s TM4 Sumo MD electric motor and inverter in its Karsan
ATAK electrified midibus. The company has been developing sustainable electric-driven vehicles since 2015 and introduced its first prototype electric minibus, the Karsan JEST, in 2016.
The TM4 Sumo MD is composed of a hightorque, permanent magnet variable reluctance (PMVR) direct drive motor and automotivegrade power electronics. The new motors with the PMVR technology for external rotors can deliver 45% more torque and operating speed than previous motors in the same compact package, while reducing cost.
PMVR works by adding specially-designed soft magnetic composites (SMCS) next to the magnets. SMCS are produced through a new forming process and fabrication method by TM4. The SMCS also allows the use of simpler and smaller magnets that are easier to manufacture and that uses less rareearth in the fabrication process to account for 25% savings in magnetic material. This new bus platform is able to operate with a range of up to 300km on a single charge.
Dana is also a key contributor in the development of the vehicle control software, through the supply of hardware and services related to its TM4 Neuro 200 vehicle control unit platform and Synapps development tool.
Jim Kamsickas, president and CEO,
Dana, said: “Dana is uniquely equipped to provide full e-propulsion systems across all gross vehicle weight categories, platforms, and architectures. From fully integrated e-propulsion systems that include electric motors, inverters, gearboxes, and thermal management, to individual subsystem components designed to meet the individual requirements of a customer’s vehicle, our Spicer Electrified with TM4 solutions are revolutionizing power conveyance and positioning Dana as a leader in the evolution of mobility.”
Dana has been collaborating with Mecalac to develop a customized e-drivetrain system for the new Mecalac e12 electric compact wheeled excavator.
Featuring Spicer 112 axles and a Spicer
367 shift-on-fly transmission, the Mecalac e12 wheeled excavator delivers the range, performance, and compact size required to support modern urban construction sites.
Dana has a long history of developing drivetrain systems for hybrid and electric vehicle architectures. The company also offers patented battery and electronic cooling technologies, along with fuel-cell technology. In addition, Dana engineers had extensive experience with this particular application because the diesel-powered version of this vehicle also features Spicer drivetrain components.
Aziz Aghili, president of off-highway drive and motion technologies, Dana, said: "As a tier-one supplier, we understand that the success of electrification in the off-highway industry is driven by performance. These technologies must support a smooth transition to fully integrated electric-drive technologies optimized within a single package, providing both electrified and conventional powertrain options. Dana's support for new energy vehicles has been considerable, and growing every year, as the importance of engineering for hybridization and electrification is further elevated throughout the industry."
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