E-mobility is emerging at an accelerated pace, partly because environmental, social and governance trends are becoming non-negotiable for both consumers and leaders. As concerns around climate change become more paramount, Schaeffler looks forward and embraces the numerous changes in our social, geopolitical, and macroeconomic environment as well as challenges and opportunities.
Schaeffler has been working on various technologies that will make future mobility more sustainable and efficient. The company is developing solutions for combustion engine-driven, hybrid, and all-electric powertrains with innovative ideas and creative engineering.
The hybridisation of conventional IC engines is a significant key to efficient, more sustainable and needs-based mobility, especially during this transition period. By 2030, Schaeffler expects a worldwide market share of 40 per cent for all newly registered passenger cars with hybrid powertrains. They offer a modular solution with powerful electric auxiliary drive units -hybrid modules, for this vehicle category.
The modular hybrid system is flexible and can be adapted precisely to various transmissions and motors, for instance, a hybrid module with an integrated torque converter or a hybrid module with a triple clutch. Schaeffler offers ideal solutions for the growing diversity of hybrid vehicle concepts worldwide, with its highly efficient permanent-magnet excited synchronous and asynchronous motors.
Schaeffler's innovative technology platform provides the basis for a necessary variance in the e-motor modular kit. It covers the entire performance range from 20 kW to more than 300 kW, as well as battery voltages between 48 and 800 volts. With high vertical integration, long-standing manufacturing expertise and pioneering winding technology – such as wave winding – Schaeffler develop electric motors with maximum power density and performance at compelling levels of quality.
Since 2017 Schaeffler has been mass-producing e-axle transmission, successfully ensuring optimal gear ratios and power transmission from the electric motor to the wheels for various applications. For example, in the Porsche Taycan, Schaeffler's highly efficient coaxial e-axle transmission provides the correct gear ratios at the front axle – an award-winning innovation. In 2020, Schaeffler was recognized with the prestigious PACE Award, that's regarded as the benchmark for successful automotive projects worldwide.
Schaeffler is also developing its most comprehensive drive system for electric cars, the 4in1 electric axle. It combines the components of motor, gearbox, power electronics and thermal management into an innovative overall system.
The high level of integration of the components, in combination with intelligent control and a highly engineered architecture, enables the optimum use of existing thermal energy. The system therefore stands for both an increase in electric range and an increase in comfort.The components for the electric axles are manufactured at several locations worldwide.
However, in 2021 production started at its plant in Szombathely, Hungary, Schaeffler Group's first pure e-mobility plant and its new competence centre for the manufacture of components and systems for electrified powertrains. Known as the "Factory for tomorrow", the facility has already set new standards in sustainability as the new plant's electricity is supplied by photovoltaic arrays in combination with rooftop solar panels, which will save up to 4,000 metric tons of CO2 annually.
To help conserve natural resources, the plant re-uses treated wastewater and incorporates a rainwater collection basin. It is also highly energy efficient, featuring heat pumps, an intelligent heating and cooling system, and smart LED lighting system. Schaeffler's total sustainability concept also includes on-site outdoor nature zones and an organic pond for enhanced local biodiversity.
After twenty years of research and development and, in 2018 establishing an E-Mobility division, it's fair to say Schaeffler is "All In" on Electric mobility. Schaeffler's consistent commitment to electric mobility is reflected in its significant success. Numerous delivery contracts awarded by automotive OEMs across all electrification prove that Schaeffler has successfully established itself in electric mobility.