An Investigation of Representative Customer Load Collectives in the Development of Electric Vehicle Drivetrain Durability

Abstract

To ensure the precise dimensioning and effective testing of drivetrain components, it is crucial to have a thorough understanding of customer requirements, with a particular emphasis on customer stress on these components. An accurate interpretation of customer data is essential for determining representative customer requirements, such as load collectives. The automobile industry has faced challenges in analyzing large amounts of customer driving data to obtain representative load collectives as target values in durability design. However, due to technical limitations and cost constraints, collecting data from a large sample size is not feasible. The ongoing digitalization of the automotive industry, driven by an increasing number of connected vehicles, enhances data-based and customer-oriented development. This paper investigates representative customer load collectives using cloud data from over 40,000 customer vehicles to lay the groundwork for realizing robust requirement engineering. A systematic method for analyzing big data on the cloud was introduced. The derived component-specific damage distribution from these collectives adopts a unique approach, utilizing the 1% vehicle term instead of the common 1% customer term to represent typical customer stress. This study shows that the driven mileage and the number of vehicles are crucial factors in 1% vehicle analysis. An analysis of the characteristics of the 1% vehicle is conducted, followed by an exploration to determine the required vehicle quantity for obtaining stable results. The shape parameter of the damage distribution determines the necessary number of vehicles for a reliable conclusion. Additionally, a comparative analysis of market-specific customer requirements between the US and Europe is presented, and real usage differences in customer operations are explained using an operating point frequency heatmap. The information presented in this paper provides valuable input for optimizing durability design and conducting efficient, customer-oriented tests, resulting in significant reductions in development time and costs.