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Dual-Rotor,Radial-FluxElectric
MachinesforLow-CostandHighlyEfficientDriveUnits
ZoéWeicherdingDeepDriveGmbH
May16th,2024
DeepDrive
Deeptechnical
expertiseand
motorsportspirit
QUICKFACTS
60+9
headcountnationalities
20217+years
foundedaverageworkexperience
INVESTORS
ADVISORS
PeterMertensExCTO,AudiandVolvo
GerdSchuster
ExHeadofResearch,BMW
JonasRiekeCOO,Personio
BenniMay
ExEngineer,Magna
CTISymposiumUSA15-16May2024,WeicherdingZoé,DeepDrive
TheDeepDrive
Dual-Rotor,Radial-FluxElectricMachine
Dual-Rotor,RadialFluxElectricMachines
am
+
U
W
V
+
V
U
+
W
Generalideaofdual-rotormachines
+
U
W
+
V
V
U
+
W
Replacestatorback-iron(yoke)with2ndrotor
Doubleair-gapareaandgainspaceformagnets
Advantages
Highertorqueoutputwithgivencurrent
Noironlossesinstatoryokeexcellentpartialloadefficiency
Keychallengeofdualrotors
Torquetransferfromstatortohousing
Coolingofthewinding
Thedual-rotorproblem,solvedbyDeepDrive‘swindingtechnology
CTISymposiumUSA15-16May2024,WeicherdingZoé,DeepDrive
DeepDrive’ssolutionfortheDual-RotorProblem
Counterskewedcopperbars
Laserweldedinbothsides
Hightorsionalstiffness
Distributedwavewinding
Counter-skewedstacks
Singleslotperconductor
Separatedinner+outerring
Madefromstampedsegments
Form-fittingwindingcarrier
Transferstorquetohousing
Ensurescoolingofendwinding
Madefromaluminium
Self-supported,torsionalstiffwindingtransferstorquefromairgapstoaxialendofmachine
CTISymposiumUSA15-16May2024,WeicherdingZoé,DeepDrive
Rotors
Rotorsmadefromsolidsteel
DistributedwindingwithverysmallharmoniccontentNoadditionallossesinsolidsteel
Lowalloy,structuralsteelwithgoodmagnetizationproperties
Easymanufacturingprocess
Deepdrawingofsteelsheets
Pipeproductionmethodsalternatively
Surfacemountedmagnets
Highesttorqueandpowerdensity
AdditionalCFR-sleeveinhigh-speedapplications
CTISymposiumUSA15-16May2024,WeicherdingZoé,DeepDrive
Electromagneticadvantages
Torqueandpoweroutput
30%highertorquewithsamedimensionsandmagnetmass
Highoutputpowerinwholespeedrange
Nostatoryokenoironlossesinstatoryoke
~30%lessironlossesinWLTPcycle
Lowercopperlossesforsametorqueoutput
ExcellentNVHbehaviour
<0.5%torquerippleinwholeoperatingmap
Nocriticalradialforceexcitation
VerysmallAC-lossesinwindings
Noproximityeffectfromadjacentconductor
VerylargeconductorspossiblewithoutexcessiveAClosses
speedinrpm
CTISymposiumUSA15-16May2024,WeicherdingZoé,DeepDrive
Materialcostand
manufacturingadvantages
Stator
Segmentationconcept(stampingprocess)
Offcutreducedby>90%
Winding
Nohairpinbendingandforming
Singleconductorperslot
Rotors
Deep-drawnmanufacturingprocess
Solidmaterial(low-carbonsteel)
Magnets
Minimisedmaterialusage
NoexpensiveDysprosiumandTerbium
SignificantcostpotentialofE-motorbyreducingbothmaterialcostandproductioncost
CTISymposiumUSA15-16May2024,WeicherdingZoé,DeepDrive
Integrated3LT-Typeinverter
Largeswitches
(~500ARMScurrentrating)
0
CDC
Smallswitches
(~100ARMScurrentrating)
T1
T2
T3
T4T5T6
T9T10
T7T8
CDC
Motivation
VDC
+
2
SolidrotorsandsurfacemountedmagnetssensitivetoPWM-inducededdycurrents
T11
T12
Dualrotormachine
Concept
VDC
Hybrid3LT-TypeInverter
Smallercurrentratinginmid-pointswitches
3Loperationatlowcurrent
2Loperationathighcurrent
VDC2
Advantages
>75%reductionofPWM-inducedlosses
Range-relevantoperationcoveredby3L
>99.4%inverterefficiencyin3Loperation
ReducedEMC+bearingcurrents
CTISymposiumUSA15-16May2024,WeicherdingZoé,DeepDrive
ApplicationExample
CentralDriveUnit
TheDeepDrivetechnologyimprovespowertrainsalong
twoproductlines
In-wheelCentraldrive
1.200Nm-2.600Nm/wheel
Highestcycleefficiency(20%rangeincrease)
Brakeintegrationpossible
Suitablefor19-23”rims
100–200kW/wheel
2.500–4.500Nm
200–400kW
HighWLTP+motorwayefficiency
Lowdriveunitcost
Lowweightandspacerequirements
CTISymposiumUSA15-16May2024,WeicherdingZoé,DeepDrive
Centraldrivecanbecombinedwithdifferent
concepts
gearbox
TWO-STAGEGEARBOXWITHCOUNTERSHAFTANDBEVELDIFFERENTIAL
?CoaxialPowertrain
??Classic“concept
?Focusonlowpowertrainunitcost
?Weight:78kg
TWO-STAGEPLANETARYGEARBOXANDFULLYINTEGRATEDDIFFERENTIAL
?CoaxialPowertrain
?Higherdegreeofintegrationandcomplexity
?Focusoncompactdesign&lowweight
?Weight:69kg
CTISymposiumUSA15-16May2024,WeicherdingZoé,DeepDrive
Centraldrivecombinedwithatwo-stagegearboxwith
countershaftandbeveldifferenial
?Weight:78kg
?Gearratio:6-9
?3shafts,6(oillubricated)bearings
?2radialshaftsealings(rot.@gearboxspeed)
?Oilallowedine-machine,butnotrequiredforitscooling
?Rotoraspumpingcomponenttotransportoilbacktogearboxcompartment
?Integratedparkingbrakeoptionallypossible
CTISymposiumUSA15-16May2024,WeicherdingZoé,DeepDrive
ApplicationExampleCSD450
Highlights:
Excellentcycleefficiency
50%reductionofmaterialcostcomparedtoconv.PSM
Lightweightandcompactwithintegratedinverter
Compatiblewithdifferentgearboxsolutions
Flatpowercharacteristics
Specifications
DC-Voltagenom.
650Vdc
Torque(Peak|Cont.)
430Nm|210Nm
Power(Peak|Cont.)
300kW|150kW
Max.speed
14.000rpm
Outerdiameter
255mm
Activepartweight
22kg
Magnetmass
1.05kg
Ironrawmaterial
8kg
Trq-Ripple
<0.5%
speedinrpm
CTISymposiumUSA15-16May2024,WeicherdingZoé,DeepDrive
Efficiencymap
Highlights:
>97.5%peakefficiencyincl.inverter
Focusareaofefficiencyinlowtorquearea
DrivingcycleslikeWLTPormotorwaydrivingcoincidewithhighefficiencyarea
Predictedcyclelossesofmachine+inverter:
1.0kWh/100kmforC-Segment1)vehicle
1.3kWh/100kmforD-Segment2)vehicle
Verylowdraglossesbeneficialforall-wheeldriveapplications:
<0.2kWh/100kmdraglossesinWLTP
Norangeimpactevenwithoutdisconnectingclutch
CTISymposiumUSA15-16May2024,WeicherdingZoé,DeepDrive
Efficiencymap
Highlights:
>97.5%peakefficiencyincl.inverter
Focusareaofefficiencyinlowtorquearea
DrivingcycleslikeWLTPormotorwaydrivingcoincidewithhighefficiencyarea
Predictedcyclelossesofmachine+inverter:
1.0kWh/100kmforC-Segment1)vehicle
1.3kWh/100kmforD-Segment2)vehicle
Verylowdraglossesbeneficialforall-wheeldriveapplications:
<0.2kWh/100kmdraglossesinWLTP
Norangeimpactevenwithoutdisconnectingclutch
CTISymposiumUSA15-16May2024,WeicherdingZoé,DeepDrive
StatusofValidation
RM1500(In-wheel)
RM1500CurrentStatus
Systemnowfullyoperationalwithintegrated3LT-Typeinverter,DC-LinkdisconnectingMOSFET,EMC-Filter,sealedinverter
Readyforvehicleintegration
CTISymposiumUSA15-16May2024,WeicherdingZoé,DeepDrive
Measurementboundaries:
380Vdc,ModulationRatio95%
DC-limit360A(bytestbench)
Peak:TCu=30…60°C,Tmag=35°C
Cont.TCu=210°C,Tmag=80…100°C,TC=35°C
Peakandcontinuousperformance
TorqueinNm
800
700
600
500
400
300
200
100
0
ContinuousPerformance
90
80
70
60
50
40
30
20
10
0
PowerinkW
0200400600800100012001400
Speedinrpm
TrqContMEasuredTrqSiminNm
PwrContMeasuredPwrSiminkW
Measurement
TorqueinNm
1600
1400
1200
1000
800
600
400
200
0
ShortTermPerformance
140
120
100
80
60
40
20
0
PowerinkW
0200400600800100012001400
Speedinrpm
TrqSiminNm(360Adc)◆TrqMeasured(360Adc)
-·-PwrSiminkW(360Adc)PwrMeasured(360Adc)
Verygoodagreementofpeakandcontinuousperformancewithpredictedvalues
1500Nmpeaktorquemeasured,720Nmcont.torquemeasured
120kWpeakpower,80kWcont.powermeasured
CTISymposiumUSA15-16May2024,WeicherdingZoé,DeepDrive
EfficiencyMapRM1500
Measurementboundaries:
?380Vdc,ModulationRatio95%
?Tcu=30…60°C,Tmag=35°C
Simulationboundaries:
?380Vdc,ModulationRatio95%
?Tcu=40°C,Tmag=40°C
(eDrivemotor+inverter)
~0.3%efficiencydeviationfrommeasurementtosimulation
Smallimpactoncyclelosses(+0.13kWh/100km)
CTISymposiumUSA15-16May2024,WeicherdingZoé,DeepDrive
WLTPlossanalysis
3,4
1,05
1,05
CycleLossesMeasurementvs.Simulation
LossesinkWh/100km
3,50
3,00
2,50
2,00
1,50
1,00
0,50
0,00
0,71
0,60
0,60
0,35
0,25
0,25
0,20
0,10
1,22
1,30
Measurement
(NO27Steel)
Simulation
(NO27Steel)
Target
(GO27Steel)
Future
Potential
(GaNInverter)
TeslaM3
RWDSR
LossesEM(Fundamental)LossesEM(PWM)LossesInverterLosseseAxle
Measurementboundaries:
?380Vdc,ModulationRatio95%
?Tcu=30…60°C,Tmag=35°C
MeasuredEDEfficiencyat22.5KHzin%
88
X※x
X必X
95
90
85
80
75
speedinrpm
Best-in-classWLTPefficiencycomparedtoallstate-of-theartpowertrains
+16%rangeinTeslaModel3Highland
Upto25%rangeincreasewithfurtheroptimizationspossible
CTISymposiumUSA15-16May2024,WeicherdingZoé,DeepDrive
Conclusion&Outlook
Conclusion
Efficiencyisstillamaindriverforthedevelopmentofelectricdriveunits
Thepresenteddual-rotorradialfluxtopologycombineshighefficiencywithlowmaterialcosts
Dual-rotorin-wheelorcentralmotorsarethemostefficientelectricpropulsionsystemavailabletoday,increasingvehiclerangebyuptoover20%
Differenttypesofgearboxesenableeasyintegrationintotightvehicledesignspaces
Outlook
VehicleintegrationofCentralDriveandfunctionalvalidationinreal-worlduse-cases
Designvalidationwithfocusonlifetime,sealingsandvibrationproofnessongoing
Furtherimprovementofsystemefficiencybyupcominginvertertechnologies(e.g.GaN/vGaN)
CTISymposiumUSA15-16May2024,WeicherdingZoé,DeepDrive
CTISymposiumUSA15-16May2024,WeicherdingZoé,DeepDrive
DeepDrive
Buildingthecategoryleaderinelectricmotors.
2024
CONFIDENTIAL
2
Despitearamp-upofEVs,thetransportsectorwillstillemit~50GtCO2-Weneedtobefaster
OILDEMANDFORPASSENGERCARSANDTWO-THREE-WHEELERSmb/d
28
26
24
22
20
18
16
14
12
10
8
6
4
2
0
~50GtCO2cumulativeemissionsbetween2023
and2050
Two-/Three-wheelersPassengervehicles
202520302035204020452050
Source:Systemiq,2024
CONFIDENTIALDeepDrive
RadicalInnovation
High-TechCompanies
Partnership
TheSolution:
RADICALINNOVATIONfromHIGH-TECHCOMPANIESinPARTNERSHIPwithestablishedplayers
3
CONFIDENTIALDeepDrive
Establishedautomakersareunderunprecedentedpressure
PROBLEMSWITHTHEPRODUCT
Costgapbetweencombustionandelectricvehicles
Rangeofelectricvehiclesisnotlongenough
Strugglingwithcutting-edge“software-definedvehicles”
PROBLEMSWITHTHEORGANISATIONS
“Evolutionarydevelopment”mindsetandlackofradicalinnovation
Bureaucraticlegacystructures
Developmentcyclesaretoolong
RadicalInnovation
High-TechCompanies
Partnership
4
CONFIDENTIAL
E-mobilitywinnerswillbedecidednow
GLOBALELECTRICVEHICLESSALESFORECASTUnitsofBEVsp.a.1
68m
41m
18m
8m
2025
2030
2035
2022
Newmodelsannonced
High-TechCompanies
RadicalInnovation
Partnership
OUTLOOK
MANYNEWMODELSINTRODUCEDINLATE2020S
DESIGNDECISIONSMADEINTHENEXT2-3YEARS
THESENEWMODELSNEEDTOBECOMPETITIVETOBEE-MOBILITYWINNEROVERNEXTDECADE
Notes:1)BCG,Sept2023;EVforecastincludesalllightvehicles;S&PGlobal,ElectricVehicleTrendsalllightvehicles
5
CONFIDENTIALDeepDrive
TheEVindustryisenteringexplosivegrowth
-butneedstoinnovatenow
GLOBALELECTRICMOTORSALESFORECAST
Salesvolumep.a.1,2
ε191bn
AUTOMOTIVEMAINDRIVEUNITS1
ADDITIONALMARKETS2
ε40bn
ε113bnε8bn
ε151bnε105bn
20222030
GLOBALBEVSALESFORECASTUnitsofBEVsp.a.1
19%
41%
66%
10%
%BEVsoftotal
68m
41m
18m
8m
2022202520302035
RadicalInnovation
High-TechCompanies
Partnership
Notes:1)BCG,Sept2023;EVforecastincludesalllightvehicles;2)Prescient&StrategicMarketIntelligencemarketresearch2023
6
CONFIDENTIALDeepDrive
RadicalInnovation
High-TechCompanies
Partnership
Thesolution:
RADICALINNOVATIONfromHIGH-TECHCOMPANIESinPARTNERSHIPwithestablishedplayers
7
CONFIDENTIALDeepDrive
ItstartedwithFormulaStudent……andcontinuedwiththelaunchofDeepDrive
8
CONFIDENTIAL
DeepDriveataglance
Providerofcategory-leadingelectricmotors
CUTTINGEDGE-TECHNOLOGYANDHIGHESTSPEEDOFEXECUTION
Foundedbyexpertswithleadingrolesinthefirstlarge-scaleEVprojects
Validatedcategory-leadingmotorandinvertertechtrustedbymajorOEMswithin4years
StrategicpartnershipswithOEMsandsupplierstosecurelarge-scaleoperations
Totalinvestmentof~€50mfromtopAutomotiveinvestors
SELECTEDAWARDS
German
AdvancedE-Motor
InnovationAwardTechnologyAward20242024
AwardofExcellence2024
Validationofbasetechnology
€4.3mSeedinvestment
StrategicpartnershipwithContinental
€15mSeriesAinvestment
20212022
IncorporationofDeepDrive
Firstpatentsfiledandin-wheelprototypesbuilt
Firstlarge-scaleSOPfeasible
202320242028+
Projectswith8oftop10OEMs
€30mSeriesBinvestment
Headcount:~10Headcount:~30Headcount:~65Headcount:~100Headcount:~300-400
9
CONFIDENTIALDeepDrive
Industry-leadingteamsupportedbyhigh-profileadvisors
FelixPoernbacher
Co-CEOCompany&Strategy
米R(shí)othschild&co
StefanEnder
Co-CEO
Product&Sales
KEYEMPLOYEES
Dr.AlexanderRosen
ChiefEngineerCo-founder
DeanPetrovski
Tom
Sommer
Tomasz
Skrzynski
Robert
Weingart
Sales
Production
Co-founder
ProjectsQuality
Management
l-ebasto
④
CarolaMauckMarketing
裝snowflake
Allison
Steinbarth
People
FLix
RadicalInnovation
High-TechCompanies
Partnership
KEYADVISORS
GerdSchuster
ExSVPResearch,BMW
Hans-J?rgFeigel
ExSVPInnovation,Continental
PeterMertensExCTO,
AudiandVolvo
JensWiese
ExHeadofCooperations,Volkswagen
~100
teammembers
8+yearsavg.industryexp.
+12
nationalities
65%
engineers
10
CONFIDENTIALDeepDrive
EnabledbyourDualRotortechnology-anew,patentedwayofbuildingelectricdriveunits
DUALROTORTECHNOLOGY
Rotorconsistingofinnerandouterrunnerwithtwoairgaps
Deep-drawnrotorsoutofsolidmaterial
Normally,radialfluxmachineshavejustonerotor–withourconceptwebuild“twomachinesinone”
OPTIMISEDWINDINGCONCEPT
Distributedbarwinding
Laser-weldedi-pins
Torsionallystiffwindingtorealisedualrotor
INTEGRATEDMULTILEVELINVERTER
InnovativetechwithSiCMOSFETS
Optimisedforbestefficiencyinreallifedrivingcycles
RadicalInnovation
High-TechCompanies
Partnership
11
CONFIDENTIALDeepDrive
WeunlockanewgenerationofEVswith
highestefficiencyandlowestcostdriveunits
COMPACT&POWERFUL
ULTRAENERGY-EFFICIENT
LOW-COST&SCALABLE
€1bn+
costsavingsforautomakers2
High-TechCompanies
RadicalInnovation
Partnership
ONETECHNOLOGY-TWOAPPLICATIONS
Centraldrive
(inthecenterofacar)
In-wheeldrive
(oneineachwheel)
+40%
highertorquedensity1
>800km
vehiclerangepossible
Combustion
20%
StandardEV
70%
DeepDrive
90%
Energyefficiency
Notes:1)BenchmarkedagainstTeslaModel3;forefficiencytheDeepDriveIWDiscons
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