This conference paper was submitted for presentation at the NAFEMS World Congress 2025, held in Salzburg, Austria from May 19–22, 2025.

Abstract

A CAE workflow was defined within a new Piaggio development methodology and executed to develop and assess the new Piaggio 48V electric powertrain'™s performance. The workflow involved linked CFD, EMAG and structural analyses. The objective was to anticipate fundamental results and info and reduce the economic effort associated with the physical prototyping activities. Diverse CAE suites were coupled, optimizing using Piaggio'™s procedures which were consolidated throughout the years for the of development of 2-wheelers equipped with internal combustion engines. The modular structure of those suites made in easier to incorporate the new EMAG analyses in the workflow. The MBS system simulation activities were carried out integrating the new E-powertrain models in a Piaggio'™s database, which includes libraries of subsystems such as transmissions, testbenches, etc. This approach will allow for quicker generation of future models leveraging carry-out made possible by the modular nature of such a database. The whole CAE workflow relied on a common source of truth residing in Piaggio'™s PLM system, allowing a smooth cooperation between Piaggio'™s E-Mobility and Powertrain depts. EMAG simulations were carried to assess the electric machine'™s performance and to provide input data for the subsequent CFD, MBS and structural analyses. The dynamic behavior, from a mechanical standpoint, was analyzed with multibody models, which produced KPIs'™ values and provided input data for stress analyses. CFD analyses were used to verify that the exercise temperatures were compatible with the electric machine'™s requirements and provided thermal maps for the FEM stress analyses. The structural integrity of the whole e-powertrain system was verified with combined stress and durability analyses, based on the working conditions identified during the previous EMAG, MBS and CFD campaigns. The structural FEM analyses were also used without coupling them with durability tools, to investigate functional aspects of the mechanical system. Being the CAE campaign carried out in the project'™s early stages, it allowed to reduce the physical tests and could assist the sourcing activities managed by the Purchasing dept