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This paper describes a newly developed electrified powertrain that incorporates various energy-saving improvements and is intended for use on a 2013 model year EV. Based on a 2011 model year EV that was specifically designed and engineered as a mass-produced EV, this powertrain integrates the traction motor, inverter and charging unit to achieve a smaller, lighter package for expanding application to more vehicles. Integration of the motor and inverter in particular reduced the part count for enhanced assembly ease, in addition to reducing heat transfer, noise and vibration. The specific features described in the paper are the three points below. Improving the layout of the inverter parts in order to downsize and integrate the inverter with the motor. Reducing the transfer of heat from the motor to the inverter. Reducing the excitation forces of the motor and optimizing the inverter for noise and vibration.

A simulation method has been developed for calculating the force acting on the elements, bands and pulleys of a metal pushing V-belt for CVTs and the 3-dimensional behavior of the V-belt/pulley system. This method is based on the use of a commercial FEM simulation program. The values calculated with this simulation method showed good quantitative agreement with the experimental data, thereby confirming its validity. As one example of the results calculated with this simulation method, the effect of varying the amount of misalignment on band tension and torque capacity is described.