Disconnect Actuator System (DAS) for AWD EV’s Driving System

This paper proposes DAS(Disconnect Actuator System), a system applied to an EV’s auxiliary driving system to decrease electric consumption. The proposed DAS functions to connect or disconnect the power of the EV AWD auxiliary driving system. Also, this system has a high driving performance of AWD. When only the main driving system is driven(2WD) to improve electric efficiency in EV AWD without DAS, electric efficiency is low due to drag loss generated by the rotation of internal mechanical elements in the auxiliary driving system. To reduce the drag loss of the auxiliary driving system and has the high driving performance of the AWD, A DAS that can connect or disconnect the power between the mechanical elements of the auxiliary driving system is essential. A system analysis was performed to determine the layout of the DAS, and DAS was developed using optimization by analyzing the factors related to the NVH(Noise Vibration Harshness) and seamless shifting. The method is called ‘Seamless Methodology’ in this paper. This methodology was analyzed and evaluated using AMEsim, and verified using Dynamo test and vehicle tests. Recently, it has been applied to mass-produced AWD EVs of Hyundai and Kia Motors, improving electrical efficiency by 6 to 8.3% per vehicle, and has AWD driving performance.