Automotive Engineering - March 2020 - 12

TECHNOLOGY REPORT

ELECTRONICS

JLR tackles weight with structural electronics 

Championship from 2021 onwards.  
 Of the P1316, Moore shared, "Our ability to deliver a competition-ready EV
gearbox reflects our continuing investment in transmission technology. We
have compelling technology to help
make motorsport even more exciting,
which also influences the crucial evolution of the next generation of road cars." 
 Matching e-axles to 250-kW power,
Kreisel has responsibility for motors,
inverters and batteries. Each 4WD rally
car using Xtrac's transmission technology incorporates both front and rear
e-axles. With an overall ratio of 7.90:1,
the P1316 is capable of being matched
with motors of up to 250 kW at an output speed of 15,000 rpm. Moore said
the e-axle uses an internal eccentric
rotor pump to handle lubrication, with
pressure feed to "all critical areas." It
uses a semi-dry-sump oil pickup.
The e-axle incorporates a multi-plate
ramp-type limited-slip differential with
adjustable preload as an option. The eaxle unit weighs in at around 21 kg (46.2
lb) depending on the specific application. Together with use for Rallycross
cars, the P1316 can be used by touring
cars or circuit racers. 
Although Xtrac's transmission and
driveline technology will have a dotted
line via global OEMs to high-volume
models, Moore stressed that the company would always remain at the upper
end of the market.
"There, we are the integrator, joining
the power source to the road wheels
- and whether it is an ICE or an electric
power source doesn't matter to us," he
said.
Stuart Birch

12 March 2020

Irregular surfaces 

Applications for SE already figure in
medical, military and consumer technologies (health-monitoring clothing,
curved OLED TV screens). Its big attraction is in avoiding the use of large, often
load bearing structures that are conformable, saving weight. With widespread use of SE throughout a vehicle,
Tomar said he expects electronic weight
saving to be 60%. Wiring, sensors (a
typical JLR product has more than 100)
and computing are contained within all
non-metal materials. An IP can be
turned into a functional space, Tomar

said, giving vehicle owners wide-ranging customization capability. 
The JLR LESA project started three
years ago. The dashboard was chosen
as a the most difficult cabin challenge
for it. "We took that really hard application to prove that LESA works," Tomar
said. "We have taken it through all necessary qualifications - shake, squeak,
rattle - together with very high temperatures and thermal shocks." 
It was not a straightforward R&D
course. Injection molding was tried first;
everything melted. But JLR engineers
are now confident in SE technology is
ready. "There are no five- or 10-year
issues blocking its use," Tomar said. As
part of the R&D program JLR trialed
LESA on a prototype overhead control
panel, achieving the target weight saving of 60% and minimizing the part's
thickness from 5.5 to 3.4cm (2.16 to 1.33
in.), delivering capability with minimal
mass and volume. 
 

Touching wood 

Tomar cited multiple impacts LESA can
have on functions and systems, including the capability to provide touch
controls and display information on
surfaces such as wood, without the
necessity for a screen. This could be a
boon for designers seeking wraparound buttonless presentations, help
reduce sensor count and deliver ECUs
that are part of the system, with cabling becoming flatter. Energy harvesting and the use of lightweight solar
panels are other potential assets. 
Echoing the clothing industry's use of

The layers of the JLR prototype control panel
with an ECU part of the system.
AUTOMOTIVE ENGINEERING

FROM TOP: XTRAC; JLR

Xtrac's P1316 e-axle has been developed for the
2021 to 2024 World Rallycross Championship.

Ashutosh Tomar, electrical research
technical manager at Jaguar Land
Rover (JLR) said he has absolute confidence in the potential of structural
electronics (SE) now being pioneered
by the company. Dubbed LESA
(Lightweight Electronics in Simplified
Architecture), the technology is expected in upcoming JLR models,
though its use in the next-generation
Jaguar XJ to be launched in 2020 has
not been confirmed. 
JLR is completing a successful R&D
program into printed SE, initially to introduce curved dashboard screens. The
company claims an industry first that
has the potential to radically alter vehicle interiors, with other applications
forthcoming. SE is not a new technology. Decades ago the aerospace industry was considering it as part of aircraftsurface morphing capability to adapt to
varying flight conditions. 
Building on existing printable electronic technology, Tomar said that the
system uses Computer Animated
Drawings (CAD) to virtually unfold a
part into a 2D structure, and that an
ECU is no longer necessary. "The required electronic circuit is printed onto
the flat unfolded 2D surface," he explained, "and components are mounted
before the CAD is folded back into its
original 3D. The part is then manufactured with the electronics printed into
the structure." 
 



Automotive Engineering - March 2020

Table of Contents for the Digital Edition of Automotive Engineering - March 2020

Automotive Engineering - March 2020
Contents
Editorial: The strong case for hybrids
SAE Standards News
Supplier Eye
Technology Report
Road Ready
Electrifying GM
Multimatic’s new SimCenter
New approaches in thermal management
Meet the 2020 SAE Prez
Product Briefs
Reader Feedback
Companies Mentioned, Ad Index
Q&A
Automotive Engineering - March 2020 - Intro
Automotive Engineering - March 2020 - Automotive Engineering - March 2020
Automotive Engineering - March 2020 - Cover2
Automotive Engineering - March 2020 - Contents
Automotive Engineering - March 2020 - 2
Automotive Engineering - March 2020 - 3
Automotive Engineering - March 2020 - Editorial: The strong case for hybrids
Automotive Engineering - March 2020 - 5
Automotive Engineering - March 2020 - 6
Automotive Engineering - March 2020 - 7
Automotive Engineering - March 2020 - SAE Standards News
Automotive Engineering - March 2020 - Supplier Eye
Automotive Engineering - March 2020 - Technology Report
Automotive Engineering - March 2020 - 11
Automotive Engineering - March 2020 - 12
Automotive Engineering - March 2020 - 13
Automotive Engineering - March 2020 - 14
Automotive Engineering - March 2020 - 15
Automotive Engineering - March 2020 - 16
Automotive Engineering - March 2020 - 17
Automotive Engineering - March 2020 - Road Ready
Automotive Engineering - March 2020 - 19
Automotive Engineering - March 2020 - Electrifying GM
Automotive Engineering - March 2020 - 21
Automotive Engineering - March 2020 - 22
Automotive Engineering - March 2020 - 23
Automotive Engineering - March 2020 - Multimatic’s new SimCenter
Automotive Engineering - March 2020 - 25
Automotive Engineering - March 2020 - 26
Automotive Engineering - March 2020 - 27
Automotive Engineering - March 2020 - New approaches in thermal management
Automotive Engineering - March 2020 - 29
Automotive Engineering - March 2020 - 30
Automotive Engineering - March 2020 - 31
Automotive Engineering - March 2020 - Meet the 2020 SAE Prez
Automotive Engineering - March 2020 - Product Briefs
Automotive Engineering - March 2020 - 34
Automotive Engineering - March 2020 - 35
Automotive Engineering - March 2020 - 36
Automotive Engineering - March 2020 - 37
Automotive Engineering - March 2020 - Reader Feedback
Automotive Engineering - March 2020 - Companies Mentioned, Ad Index
Automotive Engineering - March 2020 - Q&A
Automotive Engineering - March 2020 - Cover3
Automotive Engineering - March 2020 - Cover4
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