Future

eDrive Concept

GKN's advanced technology concept eDrive system packages the electric motor, power inverter and eAxle reduction gearbox within a single casing.

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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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Additive Manufacturing

GKN's additive manufacturing capabilities are allowing us and our partners to develop the next generation of automotive drivelines more rapidly.

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Carbon Fibre Propshaft

GKN has developed a lightweight, high performance carbon fibre propshaft for use on performance vehicles.

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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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eDrive Concept

eDrive Concept

GKN’s advanced technology concept eDrive system packages the electric motor, power inverter and eAxle reduction gearbox within a single casing. 

The close proximity of the components results in significant improvements in both mechanical and electrical efficiency compared to today’s technology. The optimal packaging is also more refined, as the housing helps to suppress noise and vibrations. The bespoke design means that the cooling requirements have been wholly factored in from the start, leading to further efficiencies in the system.

The sophisticated ‘wireless’ setup is approximately 15% smaller, 10% lighter, more efficient and more refined than electric vehicle systems that use separate components. GKN’s fully integrated design will enable advanced eDrive solutions to be supplied to OEMs at lower unit costs than today’s electric drivelines, paving the way for more affordable eDrive variants of mainstream vehicles.

Sinter Pump G-Rotor set

Sinter Pump G-Rotor set

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

Additive Manufacturing

Additive Manufacturing

Additive Manufacture – Product development cycle accelerator

GKN’s additive manufacturing capabilities are allowing us and our partners to develop the next generation of automotive drivelines more rapidly.

Key benefits: 

  • Ability to rapidly manufacture development prototypes
  • Enhance iterative engineering processes enabling faster innovation
  • Compete geometric freedom of design

Carbon Fibre Propshaft

Carbon Fibre Propshaft

Characteristics of Carbon Fibre material:

  • High strength-to-weight ratio
  • High rigidity
  • Corrosion resistance
  • Fatigue resistance
  • Good tensile strength
  • Low coefficient of thermal expansion
  • Electrical conductivity
  • Biologically inert
  • Self lubricating

Carbon Fibre Propshaft key benefits:

  • Lower complexity, single piece shaft eliminates centre bearing and centre joint
  • Weight reduction, can give up to 30% reduction
  • Light weight characteristics allow for increased shaft length whilst maintaining same critical speed requirements
  • Significantly lower rotational inertia
  • Design flexibility allows for NVH improvement

Sintered Rolled Helical Gears

Sintered Rolled Helical Gears

eDrive Gear (Tailored NVH)

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

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