电驱动系统还能集成到何种程度？

　　近期，有两家厂商给出了最新答案。

　　5月10日，比亚迪最新发布的十二合一智能电驱系统集成了电机、减速器、电控、整车控制器、电池管理器、直流变换器、车载充电器、配电模块、升压模块、升流模块、自加热模块、能量管理于一体。

　　但值得注意的是，盖世汽车注意到，目前来看，能够做到电驱动系统十二合一的厂商并非比亚迪一家。

　　早在北京车展期间，吉利发布的十一合一电驱动系统，以及面向全球市场的十二合一总成，同样将高集成电驱卷出新高度。据悉，该电驱动系统产品达到目前行业最高集成度，配套银河新车型。

　　那么，当以吉利、比亚迪十二合一为代表的电驱动系统逐步走进市场，这对目前以“三合一”为主流的电驱动系统市场具备怎样的颠覆和革新意义？

　　“卷”出极致，电车痛点逐一击破

　　如果说，2022年年底的特斯拉是引爆新能源汽车产业“价格战”的“始作俑者”，那么今年年初将“价格战”径直从“油电同价”推进到“电比油低”阶段的比亚迪，便是在这场“战火”中猛加“枪支弹药”的助推者。

　　即使对绝大部分车企而言，长期在“价格战”中斡旋必会遭到反噬，但“以低价抢市场”的事实已然摆在眼前，不得不参与“价格战”的主机厂们只能选择降低整车生产成本，各个细枝末节的供应链皆在车企降本诉求下承压。

　　随着碳酸锂价格大幅回落且趋稳，动力电池成本与整车定价之间的矛盾已不似以往般尖锐。但电动汽车电动化环节降本仍有较大空间，越来越多的主机厂将降本视线放在了电驱动系统领域。

　　据悉，电驱动系统占据整车成本的10%左右，是除电池之外成本第二高的部件，也决定了整车的能源效率，已成为主机厂不可忽视的降本环节。现如今，业内已有多款多合一高度集成电驱动系统产品陆续进入市场，帮助新能源主机厂降低整车成本。

　　2022年年末，比亚迪推出八合一电驱动系统，彼时，国内部分新能源主机厂的电动驱动系统还处于三电机的初级状态。2023年，东风推出马赫E十合一电驱动系统，将电驱动系统多合一集成“卷”向了新高度。

　　时至今日，电驱动系统多合一集成又现新突破。

　　据悉，此次吉利发布的十一合一电驱动系统（全球版的十二合一总成）由无锡星驱科技设计并生产。星驱科技凭借创新设计，实现了电驱动系统多合一集成的新突破：将电机、逆变器、减速器、直流变换器（DCDC）、车载充电器（OBC）、电源分配器（PDU）、电子控制系统（VCU）、高压池管理系统（HBMS）低压电池管理系统（LBMS）、热管理系统（TMS）、智能防滑控制（GWRC）、充电转换系统（EVCC）集大成，推出了十二合一电驱动系统产品，在有效降低成本的同时大幅提升了效率。

　　据悉，星驱科技研发生产的超高集成多合一电驱动系统适配前驱、后驱、四驱等多种动力需求，且采取轻量化小体积设计，整机重量79.8kg以内，较非集成系统重量轻15%以上。这意味着，整车将能获得更大的车内空间，且能在相同电量跑更长的续航里程，有效提高一体化装配效率、提高电驱系统整体功率密度。

　　时至今日，出于对动力性的不断追求，主机厂也将视线放在了提高电驱动系统的功率密度上。高功率密度电机驱动系统可以在相同体积或质量下，输出功率更大，超车加速能力和高速持续行驶能力更强。

　　眼下，“体积小型化，动力巨量化”的电机成为所有主机厂的追求，但电机功率密度的突破，始终面临着两大难题：一方面要在体积不变的情况下，实现更大的功率输出；另一方面，还要避免高功率输出损耗，以防功率浪费在产热这种无用功上。

　　星驱科技显然已攻克上述两大难关。星驱科技采用0.27mm高性能超薄硅钢片，并用高牌号、稀土扩散工艺的钕铁硼磁钢，提供更高的磁能积，实现了7.52kW/kg的电机功率密度，超行业约6kW/kg平均水平，大幅提升25%。

　　但值得注意的是，电驱动系统的高功率密度，需要更高效的电力转换效率和对更高的工作温度进行降温的能力，这就对功率器件提出了更高的要求。

　　在效率方面。盖世汽车了解到，星驱科技超高集成多合一IGBT电驱CLTC效率达到了惊人的90.04%，也是国内首款400V IGBT电驱CLTC效率突破90%的电驱总成。采用IGBT微沟槽技术，在减小器件的电荷和电感的同时，将导通区域的电压减少15%， 使电流密度更大。

　　在降温方面，星驱科技采用的IGBT微沟槽技术将多晶硅栅从横向变为纵向，提高元胞（Cell）密度和器件的散热性能，减小热阻，在极大降低工作温度的同时还延长了设备寿命，提高整车性能的可靠性和稳定性。再加上星驱科技超高集成多合一OBC效率达94%，有效减少对电池系统的负荷，并延长了电池的使用寿命，降低更换电池的频率和成本。

　　这对保障车辆正常行驶和电池安全性的重要意义不言而喻。

　　大道归一，超高集成的背后，星驱科技有何底气？

　　一般而言，多合一电驱动系统中的电机、变速器、逆变器等核心部件都是由不同的零部件公司进行开发设计。多合一集成之后，就要求一个厂家来设计、生产集成式电驱动系统，这对电驱动系统厂商对关键零部件的自研、生产和整合能力皆提出了更高的要求。

　　星驱科技是目前极少数能够做到将多系统零部件跨领域集成的厂商之一。常规意义上而言，电驱动系统中的“大三电”包括：驱动电机、电控和变速器。根据盖世汽车了解，星驱科技的研发团队已在驱动电机和电控两大主力器件领域沉浸多年，技术积淀深厚。

　　在电机领域。星驱科技去年自研的一款SPEED高速电机，最高转速可达24，000rpm，功率密度达14kW/kg。根据彼时星驱科技对媒体做的相关介绍： 

　　星驱科技SPEED 高速电机通过优化设计转子磁桥结构，配备高强度硅钢片，大幅提高了电机高速运行下的可靠性、安全性，迈向更高的工作转速。

　　更高的转速必然对散热提出更高要求。对此，星驱科技自主创新深度油冷技术，引入电子智能油泵实现全主动润滑冷却，可根据功率需求和温度场测试结果实时智能调整冷却油量，耗油道设计采用Ω形，冷却面积扩大35.3%， 360°无死角冷却，进一步提高散热效率。

　　在高速电机应用中，减速器同样是不可忽视的重要一环。盖世汽车获悉，星驱科技研发团队仅用一年时间，自主完成从设计开发到规模量产的完整流程，成功推出国内首个自研量产的同轴行星排双电机减速器。

　　据悉，星驱科技行星排双电机减速器，采用NW型双联行星轮结构，实现了4275Nm扭矩容量。此外，该减速器采用四点角接触球轴承设计，相较于锥轴承，轴承摩擦损耗降低约50% ，实现高达98.5%的效率。同时，各行星齿轮通过异相位设计技术，使齿轮啮合激励相互抵消，降低整体激励，从而大幅提升NVH性能。 

　　在电控领域，星驱科技已完整布局了400V和800V电压平台的电控产品。以星驱科技某800V高压电机控制器为例，其最高效率达99.5%，峰值功率398kW，助力整车实现更强动力、更高续航里程，适应高频快充的应用需求。

　　由此可见，星驱科技将电驱动系统“卷”向十二合一，其背后雄厚的技术研发实力和高效的技术迭代速度显然绝非一蹴而就。

　　自2021年成立起，星驱科技便长期聚焦纯电动汽车和混合动力汽车高性能电驱动系统（EDU）的研发、制造和销售，业务覆盖零部件和软件在内的全价值链。据悉，星驱科技团队在动力传动系统和电子元件领域拥有近20年的研发和制造经验。且该公司在瑞典哥德堡、中国无锡、宁波、上海均设有研发中心，并于无锡落成了集智能、绿色为一体的制造基地。

　　数据显示，截至2024年3月，星驱科技已获专利共计277项，其中35项PCT及国外发明专利，156项中国发明专利和86项实用新型专利。前文所提及的星驱科技自主创新研发的深度油冷技术，更荣获了2023年TMC年度创新技术奖。

　　与此同时，突出的技术研发实力和具备差异化竞争力的产品，也为星驱科技吸引了更多资本的目光。3月，星驱科技获得由国调基金领投，无锡市新能源产业基金、惠恒产业、惠山金服、国联新创参投的数亿元A轮融资。

　　据悉，此次融资后，星驱科技将继续拓宽业务布局，加大产品技术研发投入，努力领跑全球新能源电驱动行业。

　　还需要提及的是，电驱动系统要集成的零部件毕竟是有限的，“多合一”终有尽头。

　　当电驱动系统集成化发展到一定程度，未来，电驱动系统还将走向跨域融合，进入到中央控制+区域控制阶段，域控制器的数量和芯片数量也会随之减少。

　　彼时，电驱动系统跨域融合还会涉及电力电子技术、电动机控制技术、车辆控制技术、智能化算法等多个领域的融合。

　　换言之，随着电驱动系统与先进的传感器技术和人工智能相结合，电驱动系统厂商角逐的赛点也将逐步由“集成化”提升至“智能化”。

　　对于未来，谁会成为电驱动系统赛道的“头部玩家”，目前尚不可轻易论断。但足以明晰的事实是：今天，我们能够看到的市场内将电驱动系统卷向“十二合一”最高集成度的厂商，只有两家。

Who stands at the pinnacle of high integration and multi integration in the battle of internal competition?

To what extent can the electric drive system be integrated?

Recently, two manufacturers have provided the latest answers.

On May 10th, BYD released its latest 12 in 1 intelligent electric drive system, which integrates motors, reducers, electronic controls, vehicle controllers, battery managers, DC converters, car chargers, distribution modules, boost modules, boost modules, self heating modules, and energy management.

However, it is worth noting that GAC Motor has noticed that currently, BYD is not the only manufacturer capable of achieving a 12 in 1 electric drive system.

As early as during the Beijing Auto Show, Geely's eleven in one electric drive system and twelve in one assembly for the global market have also taken highly integrated electric drive to new heights. It is reported that the electric drive system product has reached the highest level of integration in the industry, supporting the new Galaxy model.

So, when electric drive systems represented by Geely and BYD's 12 in 1 gradually enter the market, what kind of disruptive and innovative significance does this have for the current "three in one" mainstream electric drive system market?

"Rolling" to the extreme, the pain points of the tram are broken one by one

If Tesla at the end of 2022 was the initiator of the "price war" in the new energy vehicle industry, then BYD, which pushed the "price war" from "oil and electricity at the same price" to "electricity is lower than oil" at the beginning of this year, is the booster of "guns and ammunition" in this "war".

Even for the vast majority of car companies, long-term mediation in a "price war" will inevitably face backlash, but the fact of "grabbing the market with low prices" is already present. OEMs who have to participate in the "price war" can only choose to reduce the production costs of the entire vehicle, and the supply chain of various details is under pressure under the demand of car companies to reduce costs.

With the significant decline and stabilization of lithium carbonate prices, the contradiction between power battery costs and vehicle pricing is no longer as sharp as before. However, there is still significant room for cost reduction in the electrification process of electric vehicles, and more and more OEMs are turning their attention to cost reduction in the field of electric drive systems.

It is reported that the electric drive system accounts for about 10% of the total vehicle cost, making it the second most expensive component after the battery, and also determining the energy efficiency of the vehicle. It has become an essential cost reduction factor that cannot be ignored by OEMs. Nowadays, multiple multi in one highly integrated electric drive system products have entered the market, helping new energy OEMs reduce vehicle costs.

At the end of 2022, BYD launched an eight in one electric drive system. At that time, the electric drive systems of some domestic new energy host factories were still in the primary stage of three motors. In 2023, Dongfeng launched the Mach E ten in one electric drive system, taking the integration of multiple electric drive systems to a new height.

To this day, there has been a new breakthrough in the integration of multiple electric drive systems.

It is reported that the eleven in one electric drive system (global version of the twelve in one assembly) released by Geely is designed and produced by Wuxi Star Drive Technology. Star Drive Technology has achieved a new breakthrough in the integration of electric drive systems through innovative design: integrating motors, inverters, reducers, DC converters (DCDCs), on-board chargers (OBCs), power distributors (PDUs), electronic control systems (VCUs), high-voltage battery management systems (HBMS), low-voltage battery management systems (LBMS), thermal management systems (TMS), intelligent anti slip control (GWRC), and charging conversion systems (EVCC), and launching a twelve in one electric drive system product, which effectively reduces costs while significantly improving efficiency.

It is reported that the ultra high integrated multi in one electric drive system developed and produced by Star Drive Technology is suitable for various power needs such as front wheel drive, rear wheel drive, and four-wheel drive, and adopts a lightweight and small volume design. The overall weight is less than 79.8kg, which is more than 15% lighter than non integrated systems. This means that the entire vehicle will be able to obtain larger interior space and run longer range on the same battery level, effectively improving the efficiency of integrated assembly and enhancing the overall power density of the electric drive system.

To this day, due to the continuous pursuit of power, host manufacturers have also focused on improving the power density of electric drive systems. High power density motor drive systems can provide greater output power, stronger overtaking acceleration ability, and high-speed continuous driving ability under the same volume or mass.
Image source: Electrical Configuration Data of GAC Automotive Research Institute Image source: Electrical Configuration Data of GAC Automotive Research Institute

At present, motors with miniaturization and massive power have become the pursuit of all host manufacturers. However, the breakthrough in motor power density always faces two major challenges: on the one hand, it is necessary to achieve greater power output while maintaining the same volume; On the other hand, it is also necessary to avoid high power output losses to prevent power waste on useless work such as heat generation.

Star Drive Technology has clearly overcome the two major challenges mentioned above. Star Drive Technology uses 0.27mm high-performance ultra-thin silicon steel sheet and neodymium iron boron magnetic steel with high grade and rare earth diffusion technology to provide higher magnetic energy product, achieving a motor power density of 7.52kW/kg, exceeding the industry average level of about 6kW/kg, significantly increasing by 25%.

However, it is worth noting that the high power density of electric drive systems requires more efficient power conversion efficiency and the ability to cool down at higher operating temperatures, which puts higher demands on power devices.

In terms of efficiency. GAC Motor has learned that Star Drive Technology's highly integrated multi in one IGBT electric drive CLTC efficiency has reached an astonishing 90.04%, making it the first electric drive assembly in China with a 400V IGBT electric drive CLTC efficiency exceeding 90%. Using IGBT micro groove technology, while reducing the charge and inductance of the device, the voltage in the conduction area is reduced by 15%, resulting in a higher current density.

In terms of cooling, Star Drive Technology adopts IGBT micro groove technology to change the polycrystalline silicon gate from horizontal to vertical, improve cell density and device heat dissipation performance, reduce thermal resistance, greatly reduce operating temperature, and extend equipment life, improving the reliability and stability of vehicle performance. In addition, Star Drive Technology's ultra-high integrated multi in one OBC efficiency reaches 94%, effectively reducing the load on the battery system and extending the battery's service life, reducing the frequency and cost of battery replacement.

The importance of ensuring normal vehicle operation and battery safety is self-evident.

What is the confidence of Star Drive Technology behind the unification of the main road and ultra-high integration?

Generally speaking, the core components such as motors, transmissions, and inverters in a multi in one electric drive system are developed and designed by different component companies. After the integration of multiple in one, a manufacturer is required to design and produce integrated electric drive systems, which puts higher demands on the self research, production, and integration capabilities of key components for electric drive system manufacturers.

Star Drive Technology is currently one of the few manufacturers that can achieve cross domain integration of multiple system components. In a conventional sense, the "big three electric" in electric drive systems include: drive motors, electronic controls, and transmissions. According to GAC, the R&D team of Star Drive Technology has been immersed in the fields of drive motors and electronic control for many years, with a deep technical accumulation.

In the field of electric motors. Star Drive Technology developed a Speed high-speed motor last year, with a maximum speed of 24000rpm and a power density of 14kW/kg. According to the introduction made by Star Drive Technology to the media at that time:
Image source: Star Drive Technology Image source: Star Drive Technology

By optimizing the rotor magnetic bridge structure and equipped with high-strength silicon steel sheets, Star Drive Technology's SPEED high-speed motor significantly improves the reliability and safety of the motor during high-speed operation, moving towards higher operating speeds.

Higher rotational speeds inevitably require higher requirements for heat dissipation. In response to this, Star Drive Technology has independently innovated deep oil cooling technology, introduced electronic intelligent oil pumps to achieve fully active lubrication and cooling, and can intelligently adjust the cooling oil amount in real-time according to power requirements and temperature field test results. The oil consumption channel design adopts an Ω shape, expanding the cooling area by 35.3%, and 360 ° no dead angle cooling, further improving heat dissipation efficiency.

In high-speed motor applications, reducers are also an important part that cannot be ignored. According to GAC, the R&D team of Star Drive Technology has completed the complete process from design and development to large-scale production in just one year, successfully launching the first domestically developed and mass-produced coaxial planetary dual motor reducer.

It is reported that the Star Drive Technology planetary dual motor reducer adopts an NW type dual planetary gear structure, achieving a torque capacity of 4275Nm. In addition, the reducer adopts a four point angular contact ball bearing design, which reduces bearing friction loss by about 50% compared to tapered bearings, achieving an efficiency of up to 98.5%. At the same time, each planetary gear uses out of phase design technology to cancel out the meshing excitation of the gears, reduce the overall excitation, and greatly improve NVH performance.
Image source: Star Drive Technology Image source: Star Drive Technology

In the field of electronic control, Star Drive Technology has fully laid out electronic control products for 400V and 800V voltage platforms. Taking the 800V high-voltage motor controller of Star Drive Technology as an example, its maximum efficiency reaches 99.5%, with a peak power of 398kW, helping the whole vehicle achieve stronger power and higher range, adapting to the application needs of high-frequency fast charging.

It can be seen that Star Drive Technology has rolled the electric drive system into one, and its strong technological research and development capabilities and efficient technological iteration speed are clearly not achieved overnight.

Since its establishment in 2021, Star Drive Technology has been focusing on the research and development, manufacturing, and sales of high-performance electric drive systems (EDUs) for pure electric vehicles and hybrid vehicles, covering the entire value chain including components and software. It is reported that the Star Drive Technology team has nearly 20 years of research and manufacturing experience in the fields of power transmission systems and electronic components. And the company has research and development centers in Gothenburg, Sweden, Wuxi, Ningbo, and Shanghai, China, and has established a manufacturing base in Wuxi that integrates intelligence and green technology.

According to data, as of March 2024, Star Drive Technology has obtained a total of 277 patents, including 35 PCT and foreign invention patents, 156 Chinese invention patents, and 86 utility model patents. The deep oil cooling technology independently developed by Star Drive Technology, as mentioned earlier, has also won the 2023 TMC Annual Innovation Technology Award.

At the same time, outstanding technological research and development capabilities and products with differentiated competitiveness have also attracted more capital attention to Star Drive Technology. In March, Star Drive Technology received a Series A financing of several hundred million yuan, led by the National Research Fund and invested by Wuxi New Energy Industry Fund, Huiheng Industry, Huishan Financial Services, and Guolian New Innovation.

It is reported that after this financing, Star Drive Technology will continue to expand its business layout, increase investment in product technology research and development, and strive to lead the global new energy electric drive industry.

It should also be mentioned that the components that need to be integrated into the electric drive system are limited after all, and "multiple in one" will eventually come to an end.

When the integration of electric drive systems develops to a certain extent, in the future, electric drive systems will also move towards cross domain integration, entering the stage of central control+regional control, and the number of domain controllers and chips will also decrease accordingly.

At that time, cross domain integration of electric drive systems would also involve the integration of multiple fields such as power electronics technology, motor control technology, vehicle control technology, intelligent algorithms, etc.

In other words, as electric drive systems are combined with advanced sensor technology and artificial intelligence, the competition point for electric drive system manufacturers will gradually shift from "integration" to "intelligence".

For the future, it is not easy to determine who will become the "top player" in the field of electric drive systems. But the clear fact is that today, we can only see two manufacturers in the market that have rolled electric drive systems towards the highest integration level of "twelve in one".