Reduction of electric vehicle power consumption through design optimization of front axle unitized bearing

Friction drag of bearings is a major energy loss causing parameter in a typical vehicle power train. This paper explains power consumption reduction in an electric vehicle by reducing friction drag of front axle bearings. The design parameters in bearings are modified to minimize friction drag and thus increase overall range of the vehicle. Testing results show that optimization of bearing design can result in significantly lower power consumption hence increasing vehicle efficiency. Testing methodologies are innovated and reinvented to understand the phenomenon. Testing results and calculations establish the claims in reduction of power consumption. The effect of higher energy losses due to rolling resistance are prominent in Electric-Vehicles as compared to IC-Engine cars due to significantly lower power-train losses which overshadow rolling resistance losses in conventional cars.