Powertrain Development & Electrification

Engineering drive solutions for the future of mobility

Experts in rotating machinery, delivering cost, NVH, weight and performance optimised products

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Electric Motor Design

Low cost, power dense e-machines; engineered from first concept

Electric machine design review:

Topology selection and powertrain duty cycle matching
Electromagnetic design and analysis
Modelling of high-speed dynamics
Thermal design & analysis
Rotor cooling concepts

System interaction NVH analysis with the gearbox

MIL / HIL controllability and performance optimisation

Gearbox Design

Electro-mechanical design, addressing the total product life-cycle of the gearbox and ancillary systems

Highly integrated 2:1 transmissions for xEV Hybrid and Battery Electric vehicles

Transmission for automotive applications:

(MT) Manual transmission
(AMT) Automated Manual Transmission
(AT) Automatic Transmission
(DCT) Dual Clutch Transmission
(CVT) Continuously Variable Transmission

Shift actuation systems

Aerospace transmissions for rotary craft and VTOL vehicles

Transmissions for renewable energy

Inverter and Motor Control

Hardware design and electrical-electronic-embedded software for xEV and Battery Electric vehicles

Inverter selection and powertrain matching:

Commercial off the shelf product support or bespoke hardware design
Silicon carbide (SiC) and gallium nitride (GaN)
Fast charging and bi-directional applications for vehicle-to-grid

Safety concept design

Electrical distribution busbar and wiring harness

Communication and calibration

Motor controllability modelling

Integrated housing designs considering hardware assembly and manufacturability

Controls & Electronics

Delivering powertrain controls solutions from prototype to production

Leveraging in-house expertise and a global supplier network

Model based systems engineering approach allowing traceability from customer requirements to embedded code

Plant modelling industry standard software tools

Application code development compliant with industry standards, e.g. ISO26262

Powertrain and Hybrid Supervisory controls

Testing MIL/SIL/HIL

Vehicle integration

EDU & Powertrain Integration

Considering the whole drivetrain for the vehicle platform installation

Physical EDU electric drive-unit packaging

Electro-mechanical vehicle integration with Chassis, Cooling and Electrical Distribution systems

Software and controls architecture and integration

Case Studies

48V Mild Hybrid HD Truck Passenger Car EV Wind Turbine

Customer entering electrification market with a new product range, required engineering design support.

Romax designed electric drivetrain from architecture first principles with high-volume production in mind from the outset i.e. straight to casting.

Romax using Nexus toolset eliminated the proof of concept mule development hardware phase, significantly reducing the project time and budget.

Customer, started their electrification journey with a clean sheet of paper intending to design a modular platform for their electric drivetrain solution.

Having completed a platform study to span all their applications and duty cycles, Romax developed a bespoke gearbox, electric motor, electric shift actuation and TCU hardware with an ISO26262 safety case in anticipation for a fleet trial.

Romax delivered the hardware with our suppliers and managed the testing.

We delivered both 2:1 integrated gearbox-motor and 3:1 applications complete with chassis, cooling and EDS integration ready to commence series production program.

Luxury passenger car EV development of new EDU and powertrain control system for China market.

Romax developed a bespoke gearbox, electric motor, electric park lock and electric shift actuation meeting the customer’s high spec and futured requirements. We delivered 2:1 integrated gearbox-motor, application ready integrated power electronics hardware and shift control strategy. Romax supported the OEM through the entire design lifecycle including procurement, manufacturing and testing.

Customer, had a proven track record in building industrial gearboxes and were looking to expand their portfolio with supplying hardware for wind turbines.

Having secured an order with a turbine supplier they employed Romax Design Team to provide a complete solution and support the manufacturing and testing stages to achieve GL A-DA certification.

At each stage in the process, Romax engineers provided knowledge transfer so that the customer could develop in-house skills for designing their own products.

Romax consultancy have supplied WTG solutions with traditional layouts and others of high technical challenging designs to achieve compact, light-weight designs.

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