After gathering comprehensive information about your vehicle or machine, the next crucial step in the electrification process involves optimising your electric powertrain design and ensuring that the selected components meet your operational requirements. At Lancereal, our focus on detailed analysis and precision engineering ensures that your electrified system performs reliably and efficiently, tailored to your specific application.
Running calculations to make precise recommendations
With the data collected during the information-gathering phase, Lancereal engineers begin by running a series of detailed calculations to evaluate the requirements of the electric powertrain. This step is essential to determine the right balance between performance, efficiency, and cost.
Accurate calculations of the torque and speed requirements are key to ensuring that the selected motor and gearbox can meet the vehicle’s operational demands. These calculations help identify the ideal motor size, gear ratios, and configuration that will allow the vehicle to operate at its peak performance while maintaining energy efficiency. The goal is to achieve optimal power output without compromising reliability or exceeding the system’s capacity.
Based on these detailed calculations, our engineers provide data-driven recommendations on the ideal components for your electric powertrain, including the best motor, gearbox, and control system to achieve your goals. These recommendations are tailored to your vehicle’s requirements and consider factors such as efficiency, cost-effectiveness, and component availability.
Powertrain Design and Configuration
With the analysis and calculations complete, the next step is to design the electric powertrain configuration that will bring your electrification project to life.
- Motor Selection
Choosing the right motor is critical to the success of an electrification project. Whether the vehicle requires a high-torque motor for heavy-duty applications or a more lightweight, high-speed motor for efficient mobility, Lancereal ensures that the motor’s specifications align with the performance requirements identified during the earlier analysis. Key considerations include motor type (e.g., permanent magnet, induction), efficiency ratings, and size constraints. - Gearbox and Transmission Configuration
Choosing the right gearbox and transmission setup is crucial to achieving the perfect balance between speed, torque, and energy efficiency. At Lancereal, we ensure gear ratios are precisely matched to the vehicle’s operational needs, allowing the electric motor to perform within its optimal range.
Key considerations include the type of gearing, such as planetary, worm, or helical gears, which are chosen based on the specific application. The configuration, whether it involves wheel drive, shaft output, or axle setups, is tailored to the unique requirements of the vehicle. Additionally, braking (mechanical, electrical, or hydraulic) and disengage systems are carefully selected to enhance both performance and safety.
All these factors are evaluated with space constraints, efficiency, and cost in mind, ensuring a gearbox and transmission setup that integrates seamlessly into the overall powertrain design. - Control System Design
Once the transmission selection is confirmed, Lancereal can help with choices on system architecture, matching the functionality requirements with the correct control system to suit the application. The control system governs how the electric powertrain interacts with the operator’s inputs and responds to varying load conditions.
Safety is also a critical aspect of control system design. Features like emergency stop functions, overload protection, and fault diagnostics are integrated to enhance operator and vehicle safety. By combining advanced functionality with robust safety measures, Lancereal ensures that the control system not only maximises performance but also provides peace of mind in all operating conditions.
CAD Design and customer collaboration
Once the electric powertrain design has been finalised, the next stage involves creating a detailed CAD (Computer-Aided Design) model to visualise how all components fit within the vehicle’s existing architecture.
- 3D modelling and simulation
We use CAD modelling to ensure that all components integrate seamlessly within the vehicle’s physical constraints. This step is crucial for identifying any potential issues with space, weight distribution, or component accessibility. - Programmming
Working with the customer to define the functional specification is key to the programming phase. Alongside gathering information about the powertrain, we also collect detailed insights into the machine or vehicle’s intended functionality. This helps us fully understand what the customer aims to achieve with the electrification project and identifies the level of support they may require.
With this understanding, we determine whether the project needs bespoke software development, such as custom programs, or if the in-built flexibility of the controller operating system can meet the requirements. Software development considerations also include integrating CAN (Controller Area Network) systems, ensuring seamless communication between components and achieving the desired functionality. - Customer collaboration
Collaboration with our customers is a vital part of the process. We share detailed CAD models and datasheets to gather feedback, ensuring the design aligns with the customer’s expectations and requirements. Adjustments are made based on this input, guaranteeing that the final product is fully optimised before moving to the implementation phase.
A key step in this stage is defining the scope of works. This outlines the project’s deliverables, providing clarity for both parties and establishing a shared understanding of the goals, milestones, and responsibilities. Input from both sides is crucial during this phase, as it ensures the project remains aligned with the customer’s needs while adhering to the agreed timeline and outcomes.
By working closely with our customers, we create a seamless process flow for system integration, addressing every aspect from initial design to final implementation with precision and collaboration.
Implementation and optimisation
The final step in the electrification journey is to implement the designed electric powertrain system, followed by optimising the system for real-world use.
- Component installation and testing
Once the design is approved, components are procured, installed, and integrated into the vehicle. Our engineers work with you to conduct extensive testing, verifying that the powertrain meets all logic and performance criteria.
We can be as involved in this integration stage as much or as little as the customer requires. Depending on the project and customer preferences, we offer several approaches:
- Integration Testing on In-House Test Rigs
We conduct integration testing on our in-house test rigs, using the bespoke programming and selected hardware to ensure the system’s functionality meets expectations. The customer then takes responsibility for the full integration testing on their vehicle or machine. - On-Site Support for Integration Testing and Installation
In addition to in-house testing, we can provide support at the customer’s location during integration testing and installation to ensure the system functions as intended. - In-House Full Integration
For a complete service, we can bring the customer’s machine in-house and fully integrate the powertrain and control system into the vehicle or machine. This option ensures seamless alignment between hardware and software before delivery.
- Integration Testing on In-House Test Rigs
- System optimisation
After installation, the electric powertrain undergoes a series of optimisation tests to fine-tune its operation. While the responsibility for testing the vehicle or machine ultimately lies with the customer, we can provide ongoing support as needed.
This support includes:- the adjustment of parameters to ensure smooth, accurate operation
- logging of performance data and review to check for improvements of hardware or control system
- troubleshooting of functional operations to achieve optimal performance and address any challenges that arise during product development
Precision from start to finish
Electrifying a vehicle or machine is a complex process that requires meticulous planning, detailed analysis, and precision engineering. By following a structured approach—from comprehensive information gathering to detailed calculations, design, and implementation—Lancereal ensures that every electrification project delivers on its promise of efficiency, performance, and reliability.
With our expertise, you can confidently transition to electric power, knowing that each step of the journey is optimised for success.