Modeling and Simulation of a Dual Motor eAxle for Heavy-Duty Vehicles

The evolution of transportation systems is an inevitable process, driven by technologies advancements and sustainability demands. As a result, the development of innovative powertrain solutions plays a crucial role into the automotive field, especially in an environment like the heavy-duty vehicles one. This study is based on a real case in collaboration with Iveco Group. The main goal of this work is to model and simulate a patented dual motor eAxle specifically designed for HDVs applications. This technology aims to integrate a Permanent Magnets Synchronous Motor with an Asynchronous Induction Motor. Since this is a beginning phase of this Iveco project, the primary objective is to assess the feasibility of this technology within the company's strategic plans for the near future and to identify potential modifications or integrations if necessary. The first phase of this research is a bibliographic review of what each component of this system truly represents, in order to understand which are ideally the optimal configurations of every part of the patented eAxle that could bring the system the best performances. Subsequently, a detailed analysis of the mechanical structure is conducted to understand how this can be represented through MATLAB/Simulink. Following this, the actual modeling of the dual motor eAxle structure is carried out on Simulink, according to the restrictions given by the company’s standards regarding model simulation. The goal is to develop a model with a structure and level of complexity that are similar to the existing company systems in order to have, at the end of the simulation part, a meaningful and realistic comparison. The next step involves the Simulink modeling of additional vehicle system components, including for example the inverter, the DCDC converter and the vehicle dynamics model, ensuring the most realistic way of representation. Once the complete model is established, performance tests and drive cycle simulations are conducted using the Iveco Group’s simulator. The simulations have then to be compared with the same performed tests but made on an existing company system, in order to identify which are the main differences between them and to understand if the patented invention can then be suitable for further developments. The final part is a critical analysis of the obtained results, in order to understand which are the strengths and weaknesses of the invention and to try to think about possible arrangements to improve the system.