Into the Fast Lane With Maximum Precision

Teams around the globe are already working on the drive systems of the generation after next. Among them, one young Munich-based high-tech company stands out in particular with its revolutionary approach. After achieving top results under laboratory conditions, the first practical road tests are now underway.

DeepDrive's Dual Rotor concept uses a stator that simultaneously drives an inner and an outer rotor, that’s twice the capability of conventional electric motors, which drive only one. This design enables a compact build with low consumption, reduced weight, and a high torque density. The Dual Rotor technology forms the heart of DeepDrive products: the Generator, In-Wheel and Central Drives.

Can DeepDrive’s patented Dual Rotor topology become the long-awaited game changer in electromobility? According to an independent study from April 2024 titled “A Comprehensive Study on Different Motor Topologies Used in Passenger Car EV Segment”, the answer is yes. The study identifies DeepDrive’s patented technology as a leading solution for electric vehicles.

DeepDrive plans to take this groundbreaking motor topology into small-series production by 2026, where its strengths can be maximized. Large-scale production is planned for 2028. Co-founder Dr. Alexander Rosen, CTO and lead systems engineer, is highly encouraged by this external validation. “This recognition from a respected academic source, together with our own test results, confirms the potential of the DeepDrive motor to become the standard motor of the automotive industry.”

Up to 20% to the Driving Range. 50% Less of Magnet Material

The technological leap achieved with this patented radial-flux machine is so promising that DeepDrive is already collaborating with eight of the top ten automakers on development projects. Their solution increases range by up to 20% compared to the current state of the art while significantly reducing costs: thanks to a 50% reduction in required magnet material. In numbers, that means up to 800 km of range and as much as €1 billion in savings for manufacturers in high-volume production.

Power analyzer WT5000 enables traceable efficiency verification and provides measurements required for motor certification

Small Numbers, Huge Impact

Although often described as a David-versus-Goliath situation, DeepDrive is choosing a different strategy. Instead of challenging giants head-on, the company focuses on developing electric motors in close collaboration with OEMs, a strategy that has proven highly successful, as evidenced by strategic investments from BMW i Ventures, Volkswagen through its investment fund Leitmotif, Aumovio’s venture capital unit co-pace, and a strategic partnership with Aumovio.

DeepDrive has recently continued to strengthen its senior advisory bench alongside existing advisors such as Dr. Peter Mertens, former Board Member and CTO of Audi and Volvo, to prepare for large-scale industrialization and Tier-1 readiness. Most recently, the company onboarded former Tesla and Lucid Head of Production Peter Hochholdinger as Senior Expert to support the setup of a global production footprint and first high-volume series programs.

After promising test bench results, DeepDrive’s drive systems is currently being tested by major automotive players in real life driving experiences.

The smallest measurement details can pull enormous weight in this innovation race. Improving efficiency requires pushing the limits of what’s technically possible, something the founders already explored over a decade ago through Formula Student, countless test bench trials, and work on production vehicles for major automakers.

This new generation of engineers quickly realized the massive efficiency advantages hidden in the Dual Rotor concept, and DeepDrive was born, along with two major challenges:

1. How to achieve what the world's top automotive R&D teams hadn’t yet managed?
2. How to prove that a 20% efficiency increase is achievable and reproducible?

Measurement Challenges on the Test Bench

Due to the unique design of the In-Wheel motor with its inverter integrated into the assembly, DeepDrive can only measure overall system efficiency. They measure the DC input power using the Yokogawa WT5000 Precision Power Analyzer, while torque and speed are monitored using a Kistler torque transducer. “AC measurements for determining the partial efficiency of the inverter simply aren’t possible for us,” explains Dr. Rosen.

It quickly became clear that this breakthrough technology could only be developed using a dedicated industrial-grade test bench, equipped with the WT5000 reference-class power analyzer from Yokogawa.

“We knew exactly how much precision we could get from this device,” adds co-founder Maximilian Habersbrunner. The WT5000 enables traceable efficiency verification and provides measurement results required for product certifications.

Collaboration with Yokogawa Experts

A WT5000 alone doesn’t guarantee success, expert support matters. Yokogawa’s applications engineer Ugur Gürsoy and product manager Andreas Maushammer work closely with customers like DeepDrive to ensure optimal measurement results, whether through training, workshops, or developing new measurement approaches.

Thanks to this partnership and the founders’ experience, the Dual Rotor concept has moved from theory to reality. Today, the patented ultra-efficient motor design, including its power electronics, forms the core of DeepDrive’s Generator, In-Wheel and Central Drive systems.

Ensure optimal measurement results with the latest Yokogawa power analyzer

A Second Test Bench for AC Measurements

As DeepDrive optimizes its central drive unit, a second test bench has been created, this one dedicated to high-precision AC power measurement, again using the WT5000. These results shape the performance insight for the next-generation electric motors.

Investors have taken notice. Major names such as BMW i Ventures, Aumovio’s Corporate Venture Capital Unit, Volkswagen AG through Leitmotif, UVC Partners, and Bayern Kapital have already invested in DeepDrive’s future.

Relocation near Munich 

To support rapid growth, DeepDrive has moved to a new high-tech facility in Garching near Munich, positioning itself strategically within a large research and development cluster. Together with Aumovio (formerly the automotive division of Continental), DeepDrive is developing the Drive-Brake Unit, an In-Wheel motor system with an integrated brake.

"What impressed me most is that the team didn’t just build an exceptional product, they built it from day one with scalable industrialisation in mind. The engineering maturity and production readiness I’ve seen here are truly rare at this stage of a company. Now, we’re laying the groundwork together to secure the first large-scale series order, and DeepDrive is more than ready to deliver," says Peter Hochholdinger, former Global Head of Production at Tesla and Lucid Motors.

The Road to Mass Production

If the upcoming road tests are successful, DeepDrive prepares for high-volume production, providing strong proof that high-precision measurement data can help reduce CO₂ emissions, with next-gen EVs potentially cutting them by up to 20%.

The patented DeepDrive Dual Rotor, Radial Flux machine combines an inner and an outer rotor with two air gaps, benefiting from maximum material utilization and minimal iron losses. The motor features a revolutionary distributed winding concept, which forms the foundation of the dual-rotor design. In combination with an integrated SiC-MOSFET inverter, DeepDrive’s drive units achieve system efficiencies above 98%.

The DeepDrive Dual Rotor, Radial Flux machine is also available as a Central Drive and the Generator. Thanks to its traditional configuration, it can easily replace an internal combustion engine in the vehicle chassis.

Key Benefits

• Energy efficient: up to +20% more driving range compared to the state-of-the-art,
• 50% less magnet material required,
• Cost-effective and scalable production,
• Compact, powerful, and flexible: the unit can be integrated into the wheels or used as a conventional central motor.

Learn more at www.deepdrive.tech.

By Kerstin Jarosch

Translated from German by Yokogawa Europe B.V.