compact hair‑pin eAxle for small electric cars
Model No: 45kW 3in1

45kW 3in1 – A00 electric drive assembly for small EV models

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45kW 3in1 eAD – Premium Electric Drive Assembly for A00 Small EVs

 
1. Purpose‑Built for the Booming A00 & Micro‑EV Segment
 
The 45kW 3in1 eAD (Electric Axle Drive) is a dedicated propulsion solution engineered from the ground up for China’s rapidly expanding A00‑class electric vehicle market – the segment that represents the highest volume growth in urban personal mobility and shared mobility services.
Unlike downsized passenger‑car drives, this unit is designed with the specific constraints of micro‑EVs in mind: tight underfloor space, cost‑sensitive bill‑of‑materials, and the need for exceptional energy efficiency to maximize range from small‑capacity battery packs.
By integrating the motor, single‑speed offset reducer, and inverter into one compact housing, the 45kW 3in1 enables OEMs to reduce system complexity, cut assembly time, and lower overall vehicle weight – all while delivering a peppy, responsive driving experience suitable for city commuting, campus shuttles, and last‑mile delivery fleets.
Its offset layout ensures optimal torque transmission efficiency while keeping the axial length minimal, allowing flexible placement in both front‑ and rear‑axle configurations without intruding into cabin or cargo space.
 
2. Robust Technical Specifications with Two Power Options
 
The drive unit is offered in two peak‑power variants – 35 kW and 45 kW – to match different vehicle performance targets. The motor achieves a peak speed of 8,000 rpm and delivers a consistent output torque of 125 N·m, which provides ample low‑end pull for stop‑and‑go urban traffic and gentle gradients.
Despite its robust output, the entire assembly weighs only 48 kg (without oil), achieving an impressive power‑to‑weight ratio of 0.94 kW/kg (for the 45kW variant) – a benchmark in this class. The system operates across a wide DC voltage range of 260–400 V, making it compatible with nearly all commercially available 400V battery packs used in A00 vehicles, including LFP and NMC chemistries.
The reducer features a single‑speed helical gear train with a fixed reduction ratio optimized for a top speed of 100–120 km/h, balancing acceleration and energy consumption. The integrated inverter employs silicon‑based IGBTs with a switching frequency of 8 kHz, ensuring smooth sinusoidal current delivery that minimizes motor harmonics and extends bearing life.
 
3. Advanced Hair‑Pin Winding Technology for Superior Efficiency and Thermal Performance
At the heart of the motor lies hair‑pin flat‑copper winding technology – a feature typically reserved for higher‑end EVs but now brought to the A00 segment to deliver tangible efficiency gains.
Compared to conventional round‑wire windings, the hair‑pin design achieves a copper fill factor exceeding 70% (versus 55‑60% for round wire), which directly reduces ohmic (I²R) losses by approximately 15‑18% across the entire operating map.
This improvement translates into a peak system efficiency (motor + inverter) of ≥93.5% , with efficiency remaining above 90% over more than 85% of the typical urban driving cycle.
The flat conductors also have larger surface area in contact with the stator laminations, enabling superior heat extraction – hot‑spot temperatures are reduced by 8‑12°C under sustained high‑load conditions, which minimizes thermal derating and ensures consistent power output even during repeated hard accelerations.
Moreover, the reduced copper losses mean less waste heat, allowing the use of a simpler, lower‑cost cooling system (integrated water‑glycol circuit) without compromising reliability. This efficiency advantage directly extends real‑world range – typically 5‑7% more kilometres per kWh compared to motors with conventional windings – a critical selling point for cost‑conscious urban EV buyers.
 
4. Class‑Leading Compactness, Lightweight Construction, and Packaging Flexibility
 
Weighing in at just 48 kg, the 45kW 3in1 is among the lightest integrated e‑drive units in its power class.
This remarkable low mass is achieved through several engineering innovations:
(a) a die‑cast aluminium housing that integrates the motor casing and reducer shell into a single monolithic structure, eliminating heavy bolted flanges and reducing part count;
(b) a topologically optimised ribbed frame that maintains structural stiffness while shedding unnecessary material;
(c) a close‑coupled rotor‑to‑input‑shaft design that shortens the overall axial length by 15% compared to previous‑generation units, making it easier to fit within the tight wheelbase of A00 platforms.
The compact dimensions (axial length < 350 mm) allow the drive to be mounted transversely or longitudinally as required, and its low unsprung mass (when installed on the rear axle) contributes to improved ride comfort and handling stability.
For OEMs, this packaging efficiency means they can increase battery volume within the same vehicle footprint or lower the floor height for better cabin ergonomics – both highly valued differentiators in the competitive mini‑EV market.
 
5. Proven Reliability, Rigorous Validation, and Cost‑Optimised Quality
 
The 45kW 3in1 is not a laboratory concept – it has already been awarded fixed‑supplier contractswith multiple Chinese OEMs for their mid‑ and lower‑end passenger car programmes, with cumulative production orders exceeding 150,000 units over the next 18 months.
Before reaching this stage, the drive unit underwent over 2 million kilometres of durability testing across a wide spectrum of conditions: extreme cold (-35°C) in Heilongjiang, scorching heat (45°C) in Turpan, high‑altitude passes (4,500m) in Qinghai, and corrosive coastal environments.
Key durability features include:
(a) shot‑peened and carburised gear teeth capable of withstanding 2.5 times the nominal shock load;
(b) high‑grade sealed bearings (NSK/SKF) with extended grease life and contamination‑resistant labyrinth seals;
(c) IP67 protection for both motor and inverter, ensuring flawless operation in rain, snow, and dusty construction sites.
The unit is validated for a service life of 10 years or 200,000 km under normal passenger‑car duty cycles – a benchmark that matches many larger vehicles.
Despite this robust engineering, the 45kW 3in1 is designed for cost‑optimised mass production, leveraging shared components with the 130kW and 150kW family (same inverter platform, similar gear technologies) to achieve economies of scale.
The result is a product that offers OEMs the ultimate balance of quality, performance, and affordability – enabling them to build competitive A00 EVs that meet both regulatory requirements and consumer expectations without breaking the bank.