Geely has introduced its Thunder 16-in-1 intelligent electric drive system for electric vehicles. Combining the motor, power electronics, control units, and software in a single unit, the system offers 93,8% overall efficiency, weighs 75 kilograms, and delivers a power density of 11,8 kW per kilogram. The new electric drive system will first be used in the Geely Galaxy TT.
Thunder combines 12 hardware functions and four software functions in a single electric drive unit. On the hardware side, it includes an electric motor, motor control unit, reduction gear, DC-DC converter, onboard charger, power distribution unit, high and low voltage battery management systems, vehicle control unit, thermal management system, active precharge control, and power field gateway.
The four software functions integrated into the system consist of intelligent energy management, intelligent charging management, intelligent motion control, and intelligent health management. By combining the hardware and software components under a single structure, more than 180 parts used in traditional electric drive systems have been eliminated.
Thunder's housing utilizes magnesium alloy. The electric motor, reduction gear, and mounting brackets are also housed within a common casing. The unit's total weight is kept at 75 kilograms, achieving a 15 percent weight saving compared to existing mainstream electric drive systems.
The unit's vertical height remains below 325 millimeters. Thanks to its smaller footprint, approximately 28 liters of additional space is freed up in the vehicle's trunk. The length of the high-voltage cables has been reduced by 30 percent, and the length of the low-voltage cables by 15 percent. The system's power density reaches 11,8 kW per kilogram.
Thunder operates on Geely's 800-volt high-voltage architecture. The higher operating voltage reduces the electrical current in the system, while consolidating components into a single unit shortens the energy transmission paths. This arrangement, along with improvements to the conductive surfaces, reduces transmission losses by 80 percent, contributing 0,8 points to the overall efficiency of the electric drive system.
In the power electronics section, silicon carbide, or SiC, power modules are used. SiC modules reduce switching losses by 30 percent, while large-sized SiC chips and HPDmini packaging technology reduce transmission losses by 15 percent. The Umini-Pin flat wire winding technique reduces the single-end height of the motor windings by 4 millimeters. The total length of copper wire used in a motor is shortened by approximately 1.296 millimeters, and copper-related energy loss decreases by more than 2 percent.
The electric motor uses 0,2 millimeter thick, low-tension ultra-thin silicon steel sheet. Compared to the 0,35 millimeter thick sheets commonly used in the industry, iron loss is reduced by 30 percent. The high-precision gear honing process and inverted V-shaped gear structure also reduce mechanical friction losses.
The system's overall efficiency under CLTC reaches 93,8 percent. This value, announced as a record for mass-production electric drive systems, means the Geely Galaxy TT's CLTC energy consumption drops to 10,7 kWh per 100 kilometers.
AI-powered energy management regulates power consumption under different conditions such as low temperatures, city driving, and high-speed driving. At temperatures as low as -18 degrees Celsius, approximately 7 kWh of thermal energy can be stored, reducing cabin heating energy consumption by over 40 percent.
In Thunder, electric drive and chassis control operations are combined on a single high-processing-power chip. Instruction latency, which averages 40 milliseconds in traditional control systems, is reduced to as little as 2 milliseconds. Real-time torque deviation is reduced from 3% to 1% through AI-powered yaw prediction and an adaptive PID algorithm.
The cooling system uses 54 separate cooling channels directed to different points of the electric motor. Compared to traditional oil-channel systems, this structure doubles the cooling efficiency and reduces the maximum temperature the motor can reach by 15 degrees. This prevents temperature-related power limitations under high speed, high power, and prolonged load.
The Geely Galaxy TT, using the Thunder electric drive system, consumed 8,20 kWh of energy per 100 kilometers during a test drive around Lake Qinghai. This result set a Guinness World Record for the lowest energy consumption achieved by a mass-produced electric sedan around Lake Qinghai. The test was conducted under specific road conditions, differing from standard laboratory measurements.
The rear-wheel-drive version of the Geely Galaxy TT features a single electric motor producing 245 kW, approximately 329 horsepower. The dual-motor all-wheel-drive version delivers a total of 425 kW, approximately 570 horsepower. The all-wheel-drive model accelerates from 0 to 100 km/h in 3,8 seconds.
The all-wheel-drive version of the Galaxy TT set a Guinness World Record for the longest continuous dual-vehicle drift on wet surfaces by electric vehicles, with a total distance of 46,094 kilometers. The electric drive system operated under high revs, high power, intense thermal load, and constantly varying torque demands throughout the drive.
The Geely Galaxy TT, using an 800-volt electrical architecture, will be offered with three different battery options: 52,4 kWh, 63,8 kWh, and 75,2 kWh. Depending on the motor, battery, and equipment selection, CLTC range values will vary between 540, 640, 650, and 725 kilometers.
