All the fundamental problems of electric mobility begin with 'too': too little range, too much weight of the vehicle, too little energy in the Battery and too long loading time. Founded in 2015, High Torque Drive Systems is now preparing to solve all of these problems. By means of a gearless direct drive, the founding members want to implement a range of 450 to 800 km, a lower vehicle weight, as little power as possible and a nationwide quick charging technology by 2020 in the form of a series solution with individual wheel drive and thus reformulate the electric drive.

Torque instead of speed

HP or kW are not the measured variables of HTDS in electric mobility. The power increases exponentially with increasing speed. Current electric drive systems with their short ranges prove that a high level of performance leads to rapid battery discharge. However, electric cars must have the greatest possible range with high efficiency. This requires new values ​​and, above all, a rethink. The weak point in an electric car is the limited range of action combined with a long battery charging time. There are many approaches to alleviating these disadvantages. But no system has yet fully achieved this.

Improve weight, functionality and efficiency

One way to counter this disadvantage is to reduce weight. With a compact design, the usable space in the car increases. The number of components is to be significantly reduced by means of a high level of system integration. Ultimately, the necessary flexibility should be achieved through front or rear-wheel drive or as a 4 x 4 without cardan shaft or axle / differential design. Every socket has to become a gas station. With the Synchron Direct Drive, ABS and ESP up to self-driving functions can be integrated and automatic evasive maneuvers can be implemented. The driving pleasure is not neglected because the drive has an overwhelming starting torque.

Thanks to the direct drive per wheel, losses due to a transmission are a thing of the past. The power requirement adapted to the driving situation leads to range optimization. Thanks to recuperation, the deceleration energy of the synchronous motor is consistently fed back. For an even greater range, the drive should be combinable with a fuel cell or range extender.

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Kettcar for adults creates a range of up to 200 km

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A lot of power in operation means a lot of electricity. This quickly discharges the battery and the range decreases rapidly at high speed. The drives from HTDS run extremely economically. When idling, the motor, including the controls, draws very little electricity. Values ​​are achieved that cannot be achieved with a gear motor due to the higher friction in the system. If a load acts on the HTDS drive, the power consumption increases proportionally. This means that energy is only used when the engine is under load.

High number of poles as the basis for maximum starting torque

The known disadvantages of the electric drive include the gearbox, noise, high inertia, friction losses and mechanical damage due to overload. Each gear stage mechanically reduces the efficiency. The high-performance motors "HTDS-extreme" are based on a multi-pole synchronous machine. A high number of poles results in a high starting torque and a low nominal speed. These properties are the prerequisites for efficient direct drive.

The experts have known the basics and advantages of motors with transverse flux for many years. Universities and drive specialists have long been enthusiastic about this type of engine. In 2009, the basic concept of this engine was recognized by the expert jury of the Network of Automotive Excellence (NoAE) as the drive system of the future. To date, however, industrial implementation has been the main problem. High Torque Drive Systems has dealt intensively with the production technology and the structure of the multi-pole motor and has now found a solution for series production.

The high starting torque is generated at low speeds. The battery power required to start up is therefore small. With the HTDS drive system, the focus is on the high efficiency of vehicle operation. As a direct drive, the High Torque Drive System sets new standards for clean mobility that is suitable for everyday use.

Less weight for greater range

The HTDS drive concept dispenses with combustion engines, axles, transmissions, clutches and differentials. The space gained can thus be used for the passenger cell or the cargo space. The vehicles are becoming more compact, smaller and therefore lighter without compromising comfort or safety. The drive concept thus makes a significant contribution to one of the main requirements for electric vehicles: less weight for a longer range.

Another advantage of the gearless single wheel drive is the synchronous running. This allows self-driving functions to be implemented. By precisely controlling the direct drive via the integrated sensors, new safety functions such as evasive maneuvers, parking processes, lane keeping functions and even self-driving cars can be implemented with active control movements. Advantages such as the integration of ABS and ESP in the engine control or a smaller brake system due to the existing engine brake are further building blocks for a cost-effective driving system of the future.

Statement at the 2016 trade press days