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EFI Automotive partners with NTN-SNR on a joint innovation for the electric car

Applications and market innovations

EFI Automotive and NTN SNR, world specialist in bearings

have combined their know-how to develop a unique sensor-bearing assembly for electric automotive engines.
The race for innovation, particularly around electric motors, is raging in the automotive world. To meet this demand, EFI Automotive can count on its in-house research and development department and its 300 engineers. But the group also calls on outside expertise when necessary. This was the case, for example, with NTN-SNR, the world’s leading bearing specialist, with which EFI Automotive recently joined forces. The idea was to pool their respective know-how – EFI Automotive in sensors and NTN-SNR in bearings – in order to offer a breakthrough technology. The result is a sensor-bearing assembly for automotive electric motors, unique and unique on the market.

A new device on the electric car market

“At present, in a conventional electric motor, the bearing part is independent of the associated sensors,” explains Olivier Brunel, E-mobility & Strategic development Market Manager at EFI Automotive, “the innovation of our product lies in the fact that we have succeeded in combining the sensor and the bearing in a single unit. “EFI Automotive and NTN-SNR have been working on the project for several years and are now able to offer it to their customers. For the latter, the benefits are numerous. “By combining two parts into one, we first gain in space since the assembly is more compact and therefore takes up less space in the vehicle’s engine compartment” continues Olivier Brunel, “it is also easier and faster to assemble in the factory with a reduced set of processes: there is only one part instead of six! »

A tenfold increase in precision thanks to easy assembly

In addition, the integration of the sensor into the bearing also improves the accuracy of its data: “The precision of the sensor is no longer subject to the assembly quality of the resolver/bearing/metallic target assembly”, explains Olivier Brunel, “as the system is completely integrated, mechanical tolerances are avoided and the entire dimension chain is under control”. In the end, for the customer, this solution is “more compact and lighter than a resolver, easier to assemble and its precision does not depend on the quality of assembly”.

A major innovation that does not go unnoticed

Such technological innovation has not gone unnoticed in the industrial world. This sensor-bearing assembly was first presented to the world’s leading automotive companies during the Automotive Tech Days held in Lyon in November 2018. In March 2019, Canadian company Magna, a world leader in mobility technology, awarded it its 2019 Innovation of the Year Award in the electrification category. “Receiving this prestigious award from a major industrial player in the sector is very encouraging,” says Olivier Brunel, “it rewards years of research and development at EFI Automotive and will help us to make this solution known to our customers and support them in their transition to electric vehicles».

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How can support the strategy of a GM or Ford customer worldwide?

EFI partners with the world’s leading companies

Global presence and flexibility: key assets for working with major car manufacturers

EFI Automotive works with the world’s leading automakers.

Thanks to its production sites on several continents and its high adaptability to customer needs, the group has won numerous contracts with major automakers. Today, manufacturers are thinking globally: although based in the United States, major manufacturers such as GM or Ford with whom we work, have needs on all continents. “Adam Kirwin is sales manager for EFI Automotive, he has been working with Ford for years: this type of customer is looking for suppliers who can produce as close as possible to their plants, whether in the USA, Europe or China. “EFI Automotive, which has 12 sites on three continents (Europe, USA, Asia), offers global coverage that allows it to be as close as possible to its customers when developing a project. To respond to and win the tenders launched by GM and Ford, EFI Automotive was able to mobilize its American teams from Plymouth, Michigan, near Detroit, the cradle of the two American automakers. Throughout these global projects, to best meet the client’s needs, it is imperative to set up a robust project team with a single point of contact: “This is the function of Global Account Manager” explains Adam Kirwin, “it is he or she who will coordinate the project for all the sites, manage the research, prototyping and production implementation phase, the one who will inform about the progress and possible difficulties. Its ability to share information well and to bring people of different cultures together in geographically remote areas is essential to the success of the project.

A tailor-made solution

Another of EFI Automotive’s strengths in meeting the expectations of automotive giants is its flexibility. “While Ford is a long-time customer, we were not yet referenced with GM,” explains Adam Kirwin, when they were looking for a solution to remotely automate the park brake function on their electric vehicles, we offered them not an off-the-shelf solution, but a tailor-made solution, which we developed with them. “This e-lock parking brake solution was also an opportunity for EFI Automotive to demonstrate its ability to innovate and offer new solutions for the electric and hybrid vehicle engines for which it was developed. In the end, GM was seduced by this solution, which better met its expectations and also had the advantage of being more compact and therefore easier to integrate into its engines. EFI Automotive’s Plymouth site then passed quality tests and received the TASL Approved label, which is essential to integrate the American manufacturer’s list of suppliers.

From 5,000 to 20,000 hours of development time

The duration and number of staff behind the various projects depend on the complexity of the specifications. Depending on whether we are supplying an entirely new part or a part that we already produce in series, the project could require 5,000 to 20,000 hours of development and mobilize 3 to 10 people. Then, the contracts include a production period of five years, generally renewable. For tenders related to GM and Ford, production at EFI Automotive’s American, European and Chinese sites is expected to total around 25 million parts!

Brake pedal sensor

EFI innovates

Ensure the safety and braking efficiency of electric vehicles

The multiplication of electric motorizations implies new needs such as the brake pedal sensor. This is an essential element to ensure efficient and safe braking of electric or hybrid vehicles.

Driven by regulatory and technological developments, car manufacturers are multiplying electric or hybrid vehicle projects. EFI Automotive has developed a brake pedal sensor (Brake Pedal Sensor) specifically dedicated to these new engines: “The sensor measures the pedal angle” explains Kevin Hertrich, Vehicle dynamics & new functions Market Manager, “and based on this angle, will collect information that will distribute the vehicle’s braking rather towards mechanical braking if the angle is significant or towards the electric motor’s engine brake if it is not significant“. The electric motor brake is preferred to recover energy and increase vehicle range, which is a crucial issue for electric vehicles.

The extreme need for accurate and reliable measurement

However, this can only be done when all the security conditions are met. “The safety issue is major in this type of device” confirms Kevin Hertricht, “the decision to favour this or that type of braking is taken to the degree and can have significant consequences in the event of an error, to ensure the safety of the driver, the technology of our sensor must therefore be both reliable and extremely precise.” To do this, the sensor couples a mechanical interface to a so-called rotary measurement technology: “We propose a new detection technology,” explains Kevin Hertricht, “it is non-contact between the mechanical lever and the cell, and the measurement it takes is called rotary because it allows us to know the exact position of the rotary element in relation to the static element.” In addition, the sensor incorporates a spring that suppresses hysteresis effects that occur when there is “slack” in the mechanical connections and that can distort the measurements.

EFI Automotive’s safety expertise

In the automotive industry, safety is regulated by ISO 26262 and the level of requirements by ASIL (Automotive Safety Integrity Level) ranging from A to D. “EFI Automotive has recognized expertise in ASIL,” recalls Kevin Hertrich, “with this brake pedal sensor, customer demand is in ASIL C but we have already responded to calls for tenders for ASIL D level sensors.” Initiated as a project in 2017, serial production of these sensors is effective since the beginning of 2019. EFI Automotive sensors can be adapted to all types of crankset and vehicles. At present, production is mainly for PSA Group hybrid and electric vehicles. Ultimately, the volumes should be around 800,000 parts per year, all of which will be produced at the Beynost (Ain) site.

IAA

From 10th to 13th September

Driving tomorrow

EFI Automotive is at the IAA fair from 10th to 13th September in Frankfurt. True to its slogan “Driving tomorrow”, this year’s IAA in Frankfurt is the leading international platform for the very latest developments in the world of mobility. Visitors convene to see for themselves the hottest brands, suppliers and newcomers in the industry, as well as innovative mobility service providers, high-tech companies and start-ups from all over the world.