GKN exec sees signs of electrification going mainstream

AUTOMOTIVE NEWS EUROPE MONTHLY MAGAZINE

Ray Kuczera: "In the past if you saw an electric-drive vehicle it was generally quirky looking."

Peter Sigal
Automotive News Europe
March 31, 2018 06:01 CET

As GKN Driveline's senior vice president for engineering, Ray Kuczera is at the forefront of the supplier's electrification plans as the industry moves toward mainstream acceptance of the technology. Kuczera discussed this and other topics with Automotive News Europe correspondent Peter Sigal.

GKN has recently raised its forecast for electric driveline sales. What are you seeing in the market that gives you the confidence to do this?

There are a lot of different things moving the market. We have seen some vehicles [that use GKN components] become very successful. For example, the Volvo XC90 plug-in hybrid started out with a very low volume forecast but it has since ramped up. The manufacturers are also designing vehicles that are more appealing to the mainstream. In the past if you saw an electric-drive vehicle it was generally quirky looking.

Do you see electrification solutions such as 48-volt mild hybrids and electric axles gaining ground faster than full-electric vehicles?

Yes, not everybody is ready to make the full leap, and neither is the infrastructure. If you look at the time it takes to charge an electric vehicle, even if you have Tesla’s Supercharger, if there are five people ahead of you then you can have a pretty long wait. Hybridization is a great way to bridge that gap while we see the infrastructure being constructed.

Are the European and North American markets moving at different speeds toward electrification?

We always see differences between regions. It seems the Europeans are a little more accepting, and they’ve been more aggressive on fuel economy standards. A lot of this is driven by consumer desire as well as legislation, but we’re confident that this move will be a longer-term global trend.

GKN has orders worth 2 billion pounds ($2.84 billion) for electric-drive technology on its books. What are the main components?

It is a combination of mechanical gearboxes for electric axles and complete e-axles with the electric motor and inverter integrated. We're seeing that a lot of automakers are moving in the direction of integration.

GKN's axles and gearboxes are found largely in high-end or niche vehicles from Porsche, BMW, Land Rover and Volvo. Do you have orders from volume automakers?

Yes, we have several orders for mass-market vehicles, but it's too early in the cycle to be able to say who they are. I can say that we are seeing demand from mainstream small SUVs. Our electric driveline systems are also on vehicles such as the Mitsubishi Outlander [plug-in hybrid], which is proving a big seller in Europe.

What is the difference between designing components for electric drive versus internal combustion drivetrains?

The focus is always on silence and efficiency. You want to have no NVH (noise, vibration and harshness) and you want to have a very efficient package. The main difference with full-electric vehicles is that NVH becomes incredibly important because every noise becomes much more audible in the vehicle. Efficiency is key because batteries are expensive, so the more efficient the gearbox is, as the last link in the chain before the wheels, the more efficient the entire system is.

How do you ensure a quieter mechanical operation?

It's largely in tolerances. GKN has a lot of experience in designing axles and transmissions for electric vehicles, so we know where to look to make the system silent. It’s also in design and having a good understanding of the complete system.

Does that make some electric-drive components more expensive?

In general, a little bit. You're packing a lot into very small packages with e-axles. You have several stages of gearing, and you still have the components you would have in a traditional axle, such as a differential.

GKN has been a leader in all-wheel-drive systems. Now, however, some SUVs and crossovers are being launched with just front-wheel drive. Are you optimistic about the future of all-wheel drive?

I still think the future is great for all-wheel drive. There are a lot of fuel-saving technologies that can be put into an AWD system to offset the traditional losses, including GKN's Active Connect system. In general, you might see some of the budget-minded crossovers not having AWD, but a lot of people are still demanding it because of the safety and drive-ability aspects. One thing we will see for sure is a shift from mechanical AWD to the use of e-AWD, or electric axles. We're really excited about that. When you add an electric axle, you get not only the benefits of AWD but also the benefits of having a hybrid. You're getting two things from one product.

MEET THE BOSS

NAME: Ray Kuczera
POSITION: GKN Driveline Senior Vice President Engineering
AGE: 43
STARTED CURRENT JOB: April 2016

Suppliers and automakers are now competing for talent with pure technology companies. What can you do to attract the best engineers and developers?

We have to realize that the next generation of engineers value things a little bit differently. They value their time differently. They value the way they are led, and the way they are taught. We need to make sure we have an inviting environment. We've been trying to increase the fun quotient a bit to compete for talent.

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