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Published- July 2021
Number of pages – 125
2023 Update Coming Soon
Transmission has always been an important part of every vehicle running on our roads today. Fuel economy, acceleration, driving comfort and pleasure are critical parameters of a vehicle buyer’s purchasing decision and very closely related to the choice of transmission on offer.
In EVs, the role of transmission in a buyer’s purchasing decision will not be as relevant as it is in a gas-powered vehicle. The reason being, in a gas-powered vehicle that operates between 1,000-7,000 RPM, transmission acts as an intermediary between engine and wheels.
It allows engine RPM reduction by many factors to be transmitted in a smooth manner to the wheels. But, in the case of EVs, 100% of rated torque is available at 0 RPM and the motor has a flat torque curve. A single or 2-speed transmission does the job as compared to 6,7,8 or now even 10-speed automatics.
As EV sales crossed 3M units in 2020, they still make up for just ~6% of global passenger car sales, but in a year where global passenger car sales at ~56M units, contracted by 17%(YoY), the EV sales grew by 43%(YOY). This is the reason why the Electric Vehicle transmission market is a greatly debated topic of discussion in the automotive transmission industry today.
The single-multi speed EV transmission will grow in line with the growth in low and medium-range EVs, as the cost is a major factor there. But, in the mid-size and premium vehicle category, we expect E-axles (motor+ transmission+ power electronics) to replace 1-2 speed transmission, as more PHEVs are launched in coming years.
The target market in Europe will be both sedans and SUVs/Crossovers. In USA the main market will shift from passenger cars to trucks, SUVs and crossovers as OEMs are targeting this market with high powered vehicles. China will have a mix of all vehicle types as the maturity of EVs in that market is higher than other regions. Rest of the world will look out for long range vehicles and decreased pricing.
Transmission in fully electric vehicles is much simpler compared to an ICE vehicle but will hold a larger share of the overall price. Since efficiency of the overall vehicle is the main concern right now, motor efficiency will be one of the key elements as well as decreasing various transmission losses for the vehicle.
Since overall efficiency increase will be an addition of all improvements, OEMs are looking into all possibilities to increase efficiency across the spectrum of technology including software.
Honda announced critical next steps in the establishment of its EV Hub in Ohio, which will lead the company’s journey to a North American electrified future.
Marysville Auto Plant (MAP) MAP will begin preparing for EV manufacturing as early as January 2024 by merging its two current production lines, which make vehicles powered by internal combustion engines and hybrid-electric vehicle systems. Consolidating operations to a single line will allow MAP to begin constructing the infrastructure required for EV manufacture.
Read our E-axle report to know more about it.
BEVs (Battery electric vehicle) accounted for 71% of total EV sales in 2018 ,76% in 2019 and 78% in 2020, and in China which accounts for 40% of global EV market, the BEVs accounted for 81% of total EV sales. About 39% of EVs sold in China were compact hatchbacks powered by 25-40kWh battery, 80-120 hp motor and single speed transmission. Making it the biggest EV transmission market.
In the US, Tesla accounted for 70% (328k units) of all EVs sold in 2020, all of them had single-speed transmission, making it the third biggest market. The EV transmission market in the US will have the highest average price as power output in the vehicles sold in the USA is much higher. There is also high penetration of E-axle in Europe.
In Europe, EV sales were driven by PHEVs in 2018 and the best-sellers including Mitsubishi Outlander, BMW 225 Series Active Tourer and Mini Countryman, all had e-axles instead of individual transmission. But in 2019 and 2020, BEVs accounted for ~65% and 55% share of EVs sold respectively, therefore creating more demand for single-speed EV transmission.
Across the globe, OEMs are launching multiple motor vehicles to increase the overall performance aspect of the vehicle. Tesla which had 13% of the plugged in market share will launch the Semi, Cybertruck as well as new Roadster.
Volkswagen Group launched I.D 3 and I.D 4 across the globe and 20 new models based on the MEB platform will hit the market over the next 3 years. The Detroit Top 3 will focus on SUVs and Trucks for the American market and SUVs for the Chinese market as they will target high performance to make up for the lost market share in volumes.
The Electric Vehicle transmission market was estimated at 3.6 Million units in 2020 and is expected to grow to 18 Million units by 2026, growing at 24% CAGR.
E-mobility is becoming more popular. Electric vehicles are becoming more common, providing smooth and sustainable mobility. However, when it comes to specific criteria and applications, e-mobility is still a work in progress.
Whether it’s (light) duty trucks navigating steep roads, sports cars requiring high peak speeds, or a trailer or caravan that needs to be hauled, there’s something for everyone. A continuously variable transmission (CVT) may be the answer in this case.
Bosch offers the CVT4EV (continuously variable transmission with pushbelt for electric vehicles), a compact multispeed transmission idea designed for electric vehicle applications that can assist meet performance criteria for a larger audience. In electric powertrains, it improves efficiency and performance while maintaining a smooth driving experience.
The pushbelt continuously variable gearbox, designed exclusively for electric vehicles, allows the electric motor to operate at its best efficiency, resulting in lower energy usage. The CVT4EV provides a relatively low cost and more compact electric motor for the same or even better performance because to the lower torque and speed needs of the electric motor. Alternatively, you can opt for a longer-range engine with the same engine.
Inmotive, a Canadian auto parts supplier, has introduced a new two-speed transmission. The new Ingear has a straightforward and reliable design that enables a more cost-effective powertrain with an increased range.
In an EV, the electric motor and the wheels are typically connected by two reduction gears, with the motor rotating about nine times for every wheel revolution. The Ingear uses a continuous chain drive and morphing sprocket to replace the second reduction gear.
In order to change the gear ratio, an actuator directs sprocket segments into position during a single rotation of the wheels. Because of the patented geometry of the Ingear, torque can flow continuously while shifting because the motor and wheels are kept in sync.
RECENT PARTNERSHIP
Suzuki and Inmotive have agreed to collaborate on the development of an Ingear 2-speed EV gearbox for a future Suzuki electric car. To improve the performance of EV powertrain units, they created the lightweight, small, and effective Ingear 2-speed gearbox. Inmotive seeks to hasten the transition to accessible zero-emission mobility on a global scale and contribute significantly to climate change mitigation.
Suzuki believes that by entering into this joint development agreement for the 2-speed EV gearbox, it will be able to reduce costs by using a smaller electric powertrain unit and increase driving performance in a variety of driving scenarios while extending the range of electric vehicles through effective use of motor torque.
An crucial part of EVs, the e-axle, will be produced on one production line at the Honda Transmission Plant in Georgia.
In order to create e-axles, a vital part of electric vehicles (EVs) that includes the electric motor, gearing components and power electronics, TMP-G will collaborate with a Honda supplier to set up a new line. The new e-axle line will be installed, owned and run by the provider in the area currently occupied by a gearbox production line that is not in use.
For use by franchised and independent workshops qualified to work on electrified vehicle (EV) powertrains, Castrol has introduced Castrol ON EV Transmission Fluids. The two new products, which are available in five-liter packs and come in D1 and D2 variants, are suitable for a variety of EVs and help to increase the range of EVs on a single charge.
The new product offers high levels of gear and bearing protection and is a fully synthetic fluid with high performance and efficiency for transmissions used with dry e-motors.
A larger family of cutting-edge Castrol ON EV fluids includes the Castrol ON EV Transmission Fluid. The selection of EV transmission fluids, EV thermal fluids, and EV greases aid in the widespread adoption of EVs by extending their range2, enabling faster charging3, and extending their useful lives4.
In order to produce new electric drive modules (EDMs) that will power future electric vehicles assembled in North America and achieve the target of 50% battery electric sales in the U.S. by 2030, Stellantis said today that it will invest a total of $155 million in three sites in Kokomo, Indiana.
The Kokomo-built EDM will be included into vehicles created on the STLA Large and STLA Frame platforms, which are expected to debut more than 25 battery electric vehicle (BEV) models in the United States between now and 2030.
The electric motor, power electronics, and gearbox are the three main parts of the EDM, which offers an all-in-one solution for electric vehicle powertrains. This module-based design increases performance and range while keeping costs down.
RECENT TRENDS
Several recent advancements in electric car transmissions have tried to improve efficiency, performance, and range. Here are a couple such examples:
Two-speed transmissions: To boost acceleration and peak speed, certain electric car manufacturers, such as Porsche and Audi, use two-speed transmissions in their EVs. The gearbox can optimise engine efficiency at both low and high speeds by adding a second gear, allowing the vehicle to achieve better performance while simultaneously preserving battery charge.
Integrated motor-transmissions: Some firms are creating electric motors with the gearbox integrated within the motor casing, decreasing the number of parts and increasing efficiency. BorgWarner, for example, has developed a motor with a two-speed gearbox integrated within the motor casing, resulting in a compact and lightweight design that boosts efficiency.
Regenerative braking systems: A frequent feature in electric vehicles, regenerative braking allows the vehicle to recover energy when slowing down or braking. Some automakers are working on transmissions that can better use regenerative braking, increasing economy and range. Oerlikon Graziano, for example, has created a gearbox that can optimise regenerative braking, increasing efficiency by up to 10%.
There are 10+ auto suppliers active in the electric vehicle transmission market and we have profiled the top 11. BorgWarner, GKN, Jatco are among the leading players but others profiled in the report are expanding aggressively to cater to multiple EV platforms and expand their share.
The powertrain (motor + transmission) of a BEV doesn’t cost more than 5-7% of total cost of the vehicle, compared to a traditional gas-powered vehicle, where powertrain cost is 18-20% of the vehicle cost.
Batteries and power electronics on the other hand account for 25-30% of the cost of the vehicle. This is the reason why many established auto component suppliers are adopting different strategies to remain profitable in the growing EV market.
For example, suppliers like Bosch and Continental, among the biggest global auto component suppliers, are not present in the electric vehicle transmission market as yet. They are extensively banking on e-axles to grow in the EV driveline market.
Suppliers like BorgWarner and ZF are essentially targeting the hybrid vehicle segment, where they have built an extensive electrified driveline portfolio and can cater to most of the mid and high-segment vehicles.
Suppliers such as Eaton and Alisson are focusing on commercial vehicles with various products for them including e-Axles, multi-speed transmission and single-speed transmission for electric buses, fleets and trucks.
In housing of transmission is the common trend across OEMs and will be the biggest threat to transmission suppliers.
