Vitesco Technologies, an international manufacturer of advanced drive technologies and electrification solutions, introduced its new Rotor Lock Actuator at the SIA POWERTRAIN event in Lille, France, held from June 19 to 20, 2024. This new module for electric vehicles (EVs) combines three key functions into a single unit: park lock functionality, precise rotor position sensing, and optionally, the brush system for externally excited synchronous machines (EESM). This integration aims to reduce complexity, packaging space, and costs for customers.
Simplifying electric vehicle design
Most electric vehicles use a mechanical park lock in the reducer gearbox in addition to park brakes at the wheels, which ensures safe parking. However, this traditional method consumes significant space within the vehicle. Vitesco Technologies’ Rotor Lock Actuator relocates the park lock functionality from the gearbox to the rotor shaft of the e-machine, resulting in a more streamlined and cost-effective system.
Robert Paul, Head of the Actuation business unit at Vitesco Technologies, stated, “The key to the success of e-mobility is the reduction of costs and complexity. By combining up to three functions in one product, our Rotor Lock Actuator enables us to offer high functionality while optimising both packaging space and costs.”
Enhanced integration and reliability
The Rotor Lock Actuator’s end-of-shaft position on the rotor allows for a smaller actuator that integrates easily into the vehicle’s drive system. This high degree of mechatronic integration reduces the space required and allows for additional functionalities, such as the brush system for EESM and the inductive Rotor Position Sensor. This integration eliminates the need for separate control units, sensors, and harnesses, further reducing costs.
The module ensures functional reliability and safety through implemented sensing redundancy, robust cyber security measures, and advanced internal diagnostics. Driven by a 12 V DC motor, the actuator can be seamlessly integrated into the drivetrain and communication networks, ensuring easy installation. The inductive Rotor Position Sensor enhances motor control, increasing the vehicle’s range and improving parking safety by minimising vehicle movement when the rotor lock is engaged. The smart interface design between the locking element and rotor prevents accidental engagement while driving, and the lock activates and deactivates in less than 250 milliseconds.
Showcasing at SIA POWERTRAIN 2024
At the SIA POWERTRAIN 2024 event, Vitesco Technologies also showcased its High-Voltage Box for electric vehicles, which represents a new approach to the system architecture for charging and conversion electronics. This technology will be supplied to the Renault Group for battery electric vehicles starting in 2025. Additionally, the company exhibited its EESM rotor, which does not require rare earth magnets, offering a cost-effective solution for high-performance electric vehicles.
Future implications
Vitesco Technologies’ Rotor Lock Actuator is a significant development in the electric vehicle industry. By integrating multiple functions into a single module, the company aims to simplify vehicle design, reduce costs, and improve overall vehicle performance and safety. This innovation aligns with the broader industry trend towards more efficient and economical EV solutions.