GKN Driveline to bring supercar hybrid tech to masses

UK-based GKN Driveline is transferring hybrid technology from super sports cars such as the Porsche 918 Spyder and BMW i8 into affordable compact vehicles. The company has developed an ‘eAxle’ module that will enable C-segment vehicles to offer buyers a plug-in hybrid option with improved performance and a reduction in CO2 emissions by more than 50%.

Commenting on the developments, GKN Automotive’s President of Engineering, Peter Moelgg said: “GKN leads the industry in eAxle technology and we want to make plug-in hybrids a simple upgrade for consumers and manufacturers. With our systems now proven in halo hybrid sports car programmes and premium SUVs, automakers are working with us to launch eAxle technology in a much broader range of vehicles. Innovations by our hardware and software engineers will place the performance and efficiency benefits of plug-ins within the reach of many more motorists.”

The new eAxle is an evolution of the system GKN designed for the Porsche 918 Spyder. The single-speed design minimises weight to just 20.9kg while optimising efficiency, installation space and costs for mass-market vehicle applications.

A two-staged gear-train with a ratio of 12.5 provides up to 203.9kgm of torque and 87.2bhp power for a dynamic pure-electric mode and balanced wheel torques for an all-wheel drive mode. An electromechanically actuated dog clutch disconnects the electric motor at higher vehicle speeds and an open coupling minimises rotating losses when disengaged. Precision engineering of the gear teeth and other acoustic measures ensure noise emissions are minimal.

The development by GKN is helping move the balance of power in vehicles from internal combustion towards electric drives. A typical C-segment plug-in hybrid could now have an engine output of around 134bhp, with a GKN eAxle supplying an additional 87.2bhp of electrical power. According to the company, the eAxle can improve 0-100kph acceleration times by several seconds, provide a useable pure electric range and reduce a vehicle’s CO₂ emission rating to less than 50g/km.

In 2015, the average fleet emissions of cars in Europe fell to 119.3 g/km and the European Union has set a target level of 95 g/km by 2021. If implemented successfully in mass market cars, the new technology is likely to cut these emissions significantly in the coming years.  

GKN’s compact and lightweight; single-speed eAxle modules can be integrated into the rear assembly of front-wheel drive vehicle platforms to provide a combination of plug-in hybrid and electric all-wheel drive functionalities.

Rainer Link, MD of eDrive Systems, GKN Driveline says: “GKN’s position as the only hybrid technology supplier that can also deliver complete all-wheel drive systems makes us an ideal partner on these programmes. Our vehicle integration teams can support automakers in the tuning of their vehicle’s eAWD mode, ensuring that the torque delivery results in the right front-rear balance and delivers the brand’s trademark driving characteristics.”

GKN first introduced the eAxle technology in 2002, and launched its first high voltage eAxle application with PSA Peugeot Citroen in 2010. The company was awarded Official Porsche Technology Partner status for its contribution to the plug-in hybrid Porsche 918 Spyder programme. It launched the world’s first two-speed eAxle in the BMW i8 plug-in hybrid and also supplies the eAxle on the Volvo XC90 T8 Twin Engine variant, which is slated to be launched in India around Q3 this year.