Azure Transit Connect
At TSI, we pride ourselves on delivering innovative solutions for electric vehicle systems, and one of our most exciting collaborations has been with Azure Dynamics. Tasked with integrating their Force Drive™ battery-electric drivetrain into the Transit Connect chassis, we had just one month to create a mounting system that would support their vision of cleaner, more efficient transportation.
The Job
Azure Dynamics needed a system that could securely suspend their electric powertrain in the Transit Connect, and they needed it fast. With limited initial data, we quickly rolled up our sleeves and got to work. The goal was clear: design a robust prototype mounting scheme that would meet all structural and dynamic requirements while isolating vibrations from the motor and road, ensuring a comfortable ride for vehicle occupants.
The Solution
Our approach was based on a streamlined, efficient engineering process that combined advanced simulation tools and rapid prototyping.
Design Exploration
With time at a premium, we leveraged our simulation capabilities to explore the design space thoroughly. Topology optimization and multi-body dynamics allowed us to understand load paths and forces throughout the system without the need for costly physical testing. This accelerated our ability to identify effective solutions.
Vibration Isolation
One critical requirement was to design a system that would reduce vibrations from both the motor and the road. Our simulation tools helped us map out the dynamic behavior of the powertrain, which in turn allowed us to design a suspension system that could provide smooth performance without compromising durability.
Prototyping and Testing
In just one month, we moved from the initial concept to delivering production-ready drawings and prototypes. Our team sourced parts, built prototype brackets, and supported testing efforts for Azure Dynamics’ first development vehicle. The result was a design that could be easily translated into mass production, combining efficiency, effectiveness, and robustness.
The Outcome
With our rapid development process, we were able to help Azure Dynamics bring the Transit Connect Battery Electric Vehicle (BEV) to life. Our prototype-level designs not only met the demanding project timeline but also laid the groundwork for scalable production solutions. The successful integration of the Force Drive™ electric drivetrain was a key milestone in Azure Dynamics’ push to be a leader in clean transportation.
Our relationship with Azure Dynamics didn’t stop there. Since completing the initial design, TSI has continued to support Azure in a variety of ways—from troubleshooting and testing to developing new components and solving complex engineering challenges. Together, we’ve been able to move the needle on what’s possible in electric vehicle technology, helping Azure Dynamics fulfill its mission to be “Part of the Solution.”
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