Emerging

Co-axial eAxle

Developed to meet tight packaging constraints and high efficiency targets, GKN's co-axial eAxle is designed so that the transmission input and output are on the same axis, helping save space.

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VL3

This VL3 sideshaft system provides a premium solution for high performance rear-wheel driven vehicles. The VL3 plunging joints in combination with their compact sealing system and a Monobloc Tubular Shaft (MTS) provide a small packaging, low weight and an adapted NVH behaviour.

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Single Speed eAxle

GKN has developed a family of single-speed eAxles for compact car applications. The lightweight design is designed for easy integration onto global platforms and generates up to 2,000Nm and 70kW of additional torque and power – enough to achieve speeds of up to 125km/h in pure electric mode.

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Multimode eTransmission

GKN's Multimode eTransmission helps combine the best of electric and combustion engine power, enabling the vehicle to move seamlessly between three different drive modes from two power sources, depending on road conditions and the type of driving required.

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Sintered Rolled Helical Gears (eDrive gears)

Noise is a key consideration when developing systems for electrified vehicles as rpm rises and higher torque capacity is needed. GKN's Sintered Rolled Helical Gears with defined density distribution result in excellent Noise, Vibration and Harshness characteristics.

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Sintered Rolled Helical Gears

GKN has developed a process for surface densification which allows accurate strengthening of defined areas of the gear. The so called “gear-rolling” followed by a case hardening operation offers very high performance while benefiting from reduced weight of the powder metal material structure.

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Forged PM Parking Gear

The Forged PM technology applied for Parking Gears in transmissions or AWD enables for specific weight saving feature while maintaining the highest strength and tailored net-shape spline features.

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Forged PM Differential Gears

The Forged PM technology enables for smaller, high efficiency differentials with weight savings and superior material performance, especially for eDrive gearboxes and for eDrive AWD power transfer units.

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Sinter Pump G-Rotor set

GKN's G-Rotor Pump overcomes the known efficiency issue over the wide temperature range caused due to different material elongations. With the GKN unique "ALL-PM-approach" only PM steels are used and result in excellent hydraulic volumetric efficiency which enables a reduction of CO2 emissions.

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Co-axial eAxle

Co-axial eAxle

 

Key Benefits:

  • Compact single-speed coaxial eAxle for electric and hybrid drive modes
  • Energy efficient eAWD functionality to maximise customer benefit
  • Semi-integrated gearbox and eMotor layout
  • Optimised for vehicle integration and light weight
  • Electronic Disconnect Differential (EDD) for highest system efficiency 
  • Allows high speed driving with minimum losses

Single speed eAxle

Single speed eAxle

Additional features beyond electric drive:

  • eAWD functionality
  • Disconnect feature —> no vehicle speed limitation caused by electric motor speed capability
  •  Compact structure for easy integration
  • Gearbox optimized for superior NVH performance

Highly efficient due to:

  • Very low driveline drag loss when disconnected and optimized gear train in connect mode
  • No energy consumption when disconnected
  • Very flexible use, can be connected to a variety of electric motors
  • Seamless engage / disengage through precise synchronization of the electric motor
  • Immediate enhancement of the acceleration / performance of the car

VL3

VL3

Key Benefits:

  • This sideshaft concept provides a premium solution for high performance rear-wheel driven and all-wheel driven vehicles
  • The all new VL3 plunging joints with their totally new track concept in combination with their compact sealing system and Monobloc Tubular Shaft (MTS) provide a small packaging, low weight and a further improved NVH behaviour
  • The outboard joint can also be combined with the new face spline design which offers additional functional and performance

Multimode eTransmission

Multimode eTransmission
  • First Multimode eTransmission on the market
  • Optimum performance in three driving modes and two different power sources
  • High efficiency, lightweight, compact design
  • Newly developed park lock system
  • High torque enables strong all-wheel drive performance in conjunction with rear eAxle
  • Technology allows for electric, series and parallel hybrid modes
  • Disconnect clutch maximises system efficiency

Sintered Rolled Helical Gears

eDrive Gear (Tailored NVH)

Application details:
Future electrified powertrains are a huge challenge for gear technology. Very high rpm in electric drives are posing an immense challenge to NVH. In addition, higher torque capacity is needed to reduce space and weight. GKN's advanced eDrive Gear processing technology combines extreme forming with surface densification technology and offers gear performance comparable to traditionally forged gears with the added benefits of NVH reducations and light weight designs.

Advantages:

  • Design freedom
  • Reduced weight
  • Intelligent density gear body
  • Tailored NVH behaviour

Selectively densified Powder Metal Helical Gears

GKN Automotive has developed a process for surface densification which allows accurate strengthening of defined areas of the gear.

Key benefits:

  • Ability to transfer high torque loads
  • NVH improvements due to better damping behaviours
  • Manufacturing process allows for more design freedom
  • Traditional weight and cost benefits of sinter process

Forged PM Gears

Application details:

At the heart of the differential is a set of four Differential Gears, also known as bevel gears: Two side gears that connect to the left and right axles and two pinions which transmit torque between the side gears. The Forged PM technology enables for smaller, high efficiency differentials with weight savings and superior material performance, especially for eDrive gearboxes and for eDrive AWD power transfer units.

Advantages:

  • Highest torque capacity gears
  • Higher strength to weight ratio
  • Higher load carrying capability
  • Net shaped forged PM gear profile, spline and retaining groove

Application details:

The main function of Parking Gears is to hold the vehicle in a static position when parked. The gears are high density , high strength steel to provide exceptional impact properties. Forged Powder Metal parking gears are forged netshape and show superior performance in terms of bending and wear resistance after case hardening.

Advantages:

  • Additional design features, e.g. internal involute splines
  • Net-shape and light weight gear design
  • Consistence high material gear design
  • Reduction of additional machining processes (e.g. Broaching)

Sinter Pump G-Rotor set

Sinter Pump G-Rotor  set

Application details:

Common pump designs typically use a mix of different materials. Hence different thermal expansion factors create performance drops during the drive cycle of a vehicle.

GKN's G-Roter Pump overcomes this efficiency issue with an unique "ALL-PM-approach". Only PM steels are used and thus the uniform thermal expansion of componets generate excellent hydralic volumetric efficiency, energy savings and enable for high reduction of CO2 emissions. It is perfectly adapted for actuation & cooling application in DCT-, HEV- and EV transmissions but as well in eAWD systems.

Advantages:

  • Tailor made design according customer needs
  • Suitable perfectly for lubrication and actuation purposes
  • Longest service life due to high quality materials
  • PM net shape advantages reduced material waste and machining costs
  • In-house performance and validation testing
  • Improved efficiency due to optimised learances / reduced CO2 emissions

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