Geely released the Thunder 16-in-1 intelligent electric drive, with magnesium alloy housing helping it win two Guinness World Records [SMM survey]

On July 16, Geely officially launched the Thunder 16-in-1 intelligent e-drive, the world’s highest-integration mass-produced 800V high-voltage electric drive system, which also earned two Guinness World Records certifications. It solves the industry technical challenge for high-performance BEV models where strong power comes with high energy consumption and energy saving limits performance, while further improving the layout of domestically developed battery, motor, and electronic control technologies.

Currently, mainstream e-drive integration solutions in the industry range from 8-in-1 to 11-in-1. The Geely Thunder e-drive upgrades to a 16-in-1 deeply integrated architecture, encompassing 12 major hardware units and four intelligent software domains. On the hardware side, it integrates modules such as the motor, electronic control, reducer, high- and low-voltage BMS, OBC, DCDC, thermal management, active pre-charging, and powertrain domain gateway; on the software side, it carries four AI algorithm domains—energy management, charging management, motion attitude control, and fault health prediction—eliminating a total of 182 redundant parts.

In terms of lightweighting, the Thunder 16-in-1 intelligent e-drive innovatively adopts a magnesium alloy integrated common housing design, with total assembly weight as low as 75 kg, 15% lighter than comparable mainstream products and with an 8% reduction in thickness. The integrated structure shortens high- and low-voltage wiring harness conduction paths, cutting electrical energy transmission loss by 80%. Combined with silicon carbide power devices and 0.2mm ultra-thin silicon steel sheets, motor copper and iron losses are significantly optimized, achieving a system combined efficiency of 93.8%, placing it in the first tier of mass-produced e-drives. According to official data, for every 1% increase in e-drive efficiency, vehicle driving range can increase by 1.5%.

At the launch event, two Guinness World Records were simultaneously announced. The first is the lowest energy consumption record for a mass-produced BEV around Qinghai Lake: the Geely Galaxy TT, equipped with the Thunder e-drive, achieved a combined power consumption of only 8.2 kWh per 100 km on the complex lake-loop route with varying elevation and temperature, effectively improving long-distance and high-speed driving range under equal battery capacity. The second is the longest continuous twin-vehicle drift on a wet surface for an EV, with the vehicle completing a 46.094-kilometer continuous drift, surpassing Porsche’s previous record and proving that the e-drive’s precise torque control and vehicle dynamic management have reached world-class levels.

Industry analysis points out that the large-scale application of the magnesium alloy integrated housing in e-drive assemblies will continuously boost demand for magnesium alloy lightweight parts. As 800V high-voltage platform car models accelerate their popularization, the penetration space of magnesium materials in the NEV powertrain field is expected to continue to widen.