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Powertrain Design Electrification

AVL is a pioneer of electrification techniques for vehicle powertrains and is familiar with all actual and promising future technologies. One of the major design tasks of the AVL design team is to find and elaborate a powertrain concept that best meets the dedicated customer vehicle concept, as well as the profile of the potential user. AVL uses most modern simulation and design techniques for early concept evaluation and verification, taking into account all the relevant aspects for an optimal system and system integration. Our business is not only the theoretical powertrain layout but even the integration into the vehicle, physical testing and design for SOP and beyond.

AVL Solution

  • Electric vehicle and hybrid system optimization including e-motor, battery, power electronics and system controls
  • Range extender solutions as a combination of an internal combustion engine with a generator
  • Conceptual design and simulation-based verification with most advanced methodologies and tools
  • Efficient and proven simulation-driven design process based on front-loading approach
  • System integration, including system controls and all other electric components
  • Integration of e-drive systems according to all functional targets of the vehicle
  • Elaboration and realization of valuable solutions with a close look on manufacturability and production costs
  • AVL e-Fusion is a highly integrated system of modular building blocks for mild and plug-in hybrids, range extender and pure electrical drives. Low in weight and size. Low in fuel consumption and cost


Broad track record of gasoline hybrids, diesel hybrids, battery electric vehicle and range extender projects, e.g.:

  • Landrover Freelander TD4_e Micro Hybrid
  • Audi A1 e-tron Battery Electric Vehicle with range extender
  • P2-Hybrid-system development for Tier 1 & OEM
  • Several battery concept studies & A-sample development for europaen OEM's
  • Battery development from concept to serial production for a Chinese OEM

Benefits at a Glance

  • Utilization of specialists for all design aspects under one roof
  • Comprehensive databases for benchmarking, concept evaluation and simulation methods allow statistically driven target and trend analysis
  • Internal research activities both on a component level (e-motors, batteries, fuel cells, range extenders) as well as on a system level (electrification and hybridization)
  • Tailor-made solutions for all kinds of applications and industries
  • Professional project management with dedicated time and cost frames