Manufacturing side layout e-axle in India for electric two wheelers

Musashi Auto Parts (India) Pvt. Ltd. (MAP-ID) is a wholly-owned subsidiary of Japan’s Musashi Seimitsu Industry Co., Ltd. In this interaction, Naoya Nishimura, CEO of Musashi India & Africa Region, discusses their product line, its USPs and export ambition from their India unit.

What are Musashi India’s current EV offerings for different segments of vehicles?

Musashi India offers a range of cutting-edge solutions in the EV space, designed to cater to different vehicle segments. For electric scooters, the company provides a 2W E-axle Side Unit, an integrated system comprising a motor, gearbox, and PCU (including MCU and VCU). This unit ensures efficient propulsion and power management, enhancing performance and extending the scooter’s range. Additionally, Musashi India delivers advanced Battery Management System (BMS) Software paired with a microcontroller to optimize battery performance.

Please tell us about your manufacturing setup and planned investment in India.

At Musashi India, our Bangalore facility in Nagadenahalli, Doddaballapur, is the cornerstone of our EV manufacturing operations. This plant currently has a capacity of 10,000 units of 2W E-axles per month, with the flexibility to scale up production as demand grows. By 2030, we target to achieve a minimum market share of 10%, driving India’s shift towards sustainable mobility.

To support this ambitious goal, we have committed an investment to enhance the mass production of EV two-wheeler e-axles at this facility. Additionally, we are focused on increasing the localisation of EV components from the current 10% to 60-70% by the end of this financial year. This not only strengthens our supply chain but also aligns with India’s Make in India initiative.

What parts does the e-axle consist of?

The e-axle is an advanced system consisting of three primary components that ensure seamless and efficient performance.

• First, the Electric Motor acts as the heart of the e-axle, converting electrical energy from the battery into mechanical energy to drive the wheels.

• Second, the Gearbox optimizes speed and torque output to suit varying driving conditions, ensuring smooth and efficient operation.

• Finally, the Power Control Unit (PCU) manages the entire powertrain system. This includes the Motor Control Unit (MCU), which controls the motor’s speed and torque, and the Vehicle Control Unit (VCU), which integrates and manages key functions like battery management, motor operation, braking, and overall vehicle performance. These components work in harmony to deliver the power, efficiency, and reliability that define our e-axle technology.

How is Musashi’s side layout e-axle technology different from regular e-axles?

Musashi’s side layout e-axle technology stands out due to its innovative design, which offers superior performance and efficiency compared to traditional e-axle systems. Here’s how it differs:

• Inline Wheel (Hub Motor): In this conventional design, the electric motor is integrated within the wheel hub. While this setup offers a compact and lightweight solution, it presents several challenges. The motor’s size is restricted by the wheel’s diameter, which inherently limits its torque and power output. This impacts both the performance and reliability of the vehicle, especially under demanding conditions. Additionally, the direct integration of the motor into the wheel hub can result in increased wear and tear due to higher unsprung weight, raising concerns about long-term practicality. This configuration is commonly used in basic EVs but remains unsuitable for high-performance models that require greater efficiency and durability.

• Mid Drive Motor: Positioned in the centre of the vehicle, typically below the seat, the motor transfers power to the wheels through a belt or chain drive. Though this offers flexibility in motor size, it’s prone to energy losses due to wear and tear on the belt, impacting efficiency and long-term performance.

• Side Layout E-Axle (Musashi’s Design): Musashi’s e-axle represents a significant advancement in electric vehicle technology. In this design, the motor is positioned alongside the rear wheel, transmitting power directly through a high-efficiency gearbox.

The key advantages of this configuration include:

• Higher Efficiency: The precision-engineered gearbox minimizes friction losses, maximizing the battery’s power utilization and enhancing the vehicle’s driving range.

• Enhanced Torque and Power: A larger motor can be integrated compared to hub motors, delivering exceptional acceleration and superior hill-climbing (high gradeability) capabilities.

• Improved Driving Experience: The e-axle’s performance provides a driving experience comparable to that of a 125cc ICE scooter, meeting the expectations of riders transitioning from traditional vehicles.

• Reduced Noise: The enclosed gearbox design significantly lowers mechanical noise, ensuring a quieter and more comfortable ride.

• Practicality and Reliability: The side layout offers a robust and durable solution, addressing common concerns in EV configurations while maintaining performance in diverse conditions.

Please tell us about your export operations from the India facility. Which parts are you exporting, and to which countries?

We are expanding our horizons beyond the domestic market and are working towards becoming a key player in the global electric vehicle (EV) component supply chain, particularly for two-wheeled vehicles. Currently, we are focused on exploring export opportunities in Asia and Africa.

As for the parts we are exporting, we primarily supply electric vehicle components, including e-axles and motors. These are crucial for driving the transition towards electric mobility in the two-wheeler segment. In terms of sales, export contributes a significant share of our revenue, with this portion steadily growing as we expand our reach and solidify our presence in these new markets. We are optimistic about scaling our export operations and aim to play a pivotal role in the global EV component supply chain.

Please tell us about your strategic partnership with Log9 for an integrated powertrain solution. How does an integrated battery and e-Axle system help optimize performance for urban settings?

Our strategic partnership integrates their cutting-edge battery technology with our e-axle systems, providing a seamless powertrain solution for electric two-wheelers. This collaboration aims to tackle two crucial challenges for urban transportation: energy efficiency and performance.

In urban settings, where stop-and-go traffic and varied terrain are common, the integrated system ensures quick acceleration, high torque for hill climbing, and efficient energy use. The combined battery and e-axle solution allows for longer ranges and improved overall durability by reducing energy losses typical of conventional powertrains.

This partnership is designed to not only enhance the performance of electric 2Ws but also to offer scalability and reliable service. We are excited about the potential impact this will have on both Indian and global markets, especially as we focus on meeting the rising demand for efficient, eco-friendly urban mobility.

Also read: Musashi starts production of EV e-2W e-axles in India