Schaeffler, the mass-production of electric motors

Ranking among the leader family-owned companies in the world, for over 70 years Schaeffler has developed inventions and innovations in the motion field for transmissions with low CO₂ emissions, in addition to the sector of electric mobility, Industry 4.0, digitalization and renewable energies.

Schaeffler dedicated hybrid transmissions deliver system power ratings of 120 kW

Its production includes high-precision components and systems for drivetrains and chassis applications, as well as rolling and sliding bearing solutions for a broad range of industrial applications. Its numbers are planetary: 83,700 collaborators, a turnover of about 14.4 billion Euros in 2019, year when it counted about 2,400 patent applications.
Coming back to our days, what are the hottest news by the brand? Certainly, the mass-production of electric motors.

The Business division course

The decision of setting up a specific vertical segment for the electric mobility dates back to the beginning of 2018. The company has progressively strengthned its competences in the electric mobility issue through a series of targeted takeovers. In 2016 it took over Compact Dynamics, a specialist in the development of innovative concepts of electric transmissions, in the same period when the joint venture Schaeffler-Paravan Technologie was developing the steer-by-wire Space Drive system, a key technology for the autonomous driving.
Another key operation was implemented with the purchase of Elmotec-Statomat, at the end of 2018, when Schaeffler added new expertise in the winding technology, so achieving comprehensive coverage of all aspects of electric motor industrialization.

Dr. Jochen Schröder, President of the E-Mobility Business Division Schaeffler AG

«We are making excellent progresses – said Dr. Jochen Schröder, President of the E-Mobility Business Division. – Our modular product portfolio enables us to offer customized volume-production solutions to meet any customer requirements. These successes in the E-Mobility Business Division reflect the company’s high standing as an automotive and industrial supplier in general. Schaeffler is a component, system and service supplier, as its comprehensive product portfolio illustrates».

Electric mobility solutions

Today Schaeffler is reaping the rewards of its decision and has started the mass-production for multiple products across all electrification levels for the electric mobility, so
establishing itself as a technological partner able to offer notable component and system know-how.

«We have successfully transformed ourselves – stated Matthias Zink, CEO Automotive Technologies at Schaefler AG – into a drive system supplier for sustainable electric mobility solutions. We have been engaged with electric mobility for more than 20 years and we understand the drive-train requirements. Our innovation capacity as a global automotive and industrial supplier plus our strong industrial skills make us a preferred partner for our customers».
This year will see the start of the mass production of hybrid modules, hybrid drive units and all-electric axle transmissions.

A PREMIUM ELECTRIC AXLE

Since 2017, Schaeffler has supplied technologies for all electrified drivetrains with mass-production of electric axle transmissions, key component of electrified systems. The company supplies optimum transmission ratios and power transfer from the electric motor to the wheels: a highly versatile component with a wide range of applications.

In Audi e tron, for instance, Schaeffler electric axle transmissions, with different structural designs, are used on both axles for all-wheel drive capability. Besides, Porsche Taycan is fitted with a high-efficiency Schaeffler coaxial electric axle transmission to provide the required transmission ratio on the front axle.
Last year, the coaxial electric axle transmission earned Schaeffler the prestigious PACE Award, regarded by industry worldwide as the hallmark for successful automotive projects.
Moreover, another plus that highlights the brand’s excellence in the solution: Schaeffler can also boast the proposal of its complete “ 3in1 electric axles”, which combine the electric motor, drive unit and power electronics in a single system. These are high-performance electric axles with advanced power density.

The technological platform of which Schaeffler avails itself for the production of electric motors is modular and highly integrated. What is brewing, concerning this? Along with a series of mass-production orders for electric motors in the passenger car sector, Schaeffler has recently reached another milestone by entering the segment of heavy-duty applications for commercial vehicles: the mass production of electric motors featuring the “wave wind- ing” technology, which provides high power density as well as advantages during assembly, is just around the corner.

INNOVATION 4.0 | MONITORING

In 2019, Schaeffler ranked second in the list of the most innovative companies in Germany according to DPMA, the German office of patents and trademarks.
Concerning this, shortly after its release, Schaeffler OPTIME condition monitoring system won the Industry 4.0 Innovation Award, prize given to products and innovations that bring
a precious or substantial contribution to the Industry 4.0 matter.
The solution focuses on the monitoring of electric motors, pumps, units and fans, that is to say drives and units that are used in very big numbers and whose conditions have been hardly or only manually monitored until now, owing to the lack of technical and economic solutions.

“Development teams and partners of Schaeffler have demonstrated a high level
of commitment to orienting OPTIME concept towards our customers’ requirements and specific work environment. We are very proud – stated Rauli Hantikainen, Head of the Industry 4.0 strategic business field – of receiving the Industry 4.0 Innovation Award for OPTIME. This prize is an acknowledgement and a motivation to go on developing solutions with pioneering spirit and innovation boost for our customers”.

The electric version of the iconic Panda

Editorial Staff

Among the special projects devised by Garage Italia, Lapo Elkann’s atelier, there is the new electric Fiat Panda 4×4 equipped with double electric motor, one on the front axle and the other on the rear one. Panda with electric powertrain is called Panda Integral-e and it has been implemented through the retrofit kit of the Icon-e project and starting from a historical Fiat Panda 4×4.
It is possible to select two driving modalities on board: Eco, which privileges traction in favour of the front axle with 80% – 20% distribution, and Sport that provides for a standard scheme of four-wheel drive, evening the distribution on both axles.
The particular customizations feature the interiors of precious Alcantara, a cutting-edge audio system purposely developed and digital instruments in the original cockpit that reports the indications on the electric traction.

Audi: a combination of electric motors for Dakar 2022

Editorial Staff

To know the details of Audi Sport prototype that will compete in Dakar 2022 we must wait until next July. However, we already know the technical specifications of the electric system powered by thermal engine in special test.
The number-seven season of the competition that will take place next January in Arabia sees the deployment of a new powertrain, a motor generator developed fully independently, by the four-rings company.
The project presentation is expected in July, then development tests will follow.
The prototype is likely to have a scheme with three electric motors, two will perform traction, a motor generator on each axis and a third motor generator to charge the battery while driving.
To face the rally in the desert, the electric traction is completed by a recharge system providing for a thermal engine, 2-litre, turbo petrol.

Seat: target is leading the automotive industry electrification in Spain

Editorial Staff

Recently, Seat Sa vehicle manufacturer has announced it will release an electric urban car in 2025; a vehicle with which the company will enter the approximately 20,000 – 25,000 Euro segment, essential to make electric mobility accessible for the vast majority of the population and to reach Green Deal goals.
Moreover, on the occasion of the 2021 Budget Conference, the Spanish company presented the ambitious Future Fast Forward plan, whose target is leading the automotive industry electrification in Spain.
The project core concerns the production of electric urban vehicles in Spain since 2025. «We want to produce electric cars in Spain starting from 2025. Our ambition is manufacturing over 500,000 electric urban cars yearly at Martorell, also for Volkswagen Group, but we need an engagement defined by the European Commission» – shared Wayne Griffiths, President of Seat Sa.

The biggest diesel plant in the world shifts to electric

Editorial Staff

It is one of the most topical 2021 news with Stellantis hashtag: the former PSA French factory, headquartered at Tremery, the biggest in the world for the production of diesel engines, will be fully reconverted to the manufacturing of electric motors.
The mega-structure was inaugurated in 2019 and this year it will produce 180,000 electric motors, with the long-term target of reaching 900,000 units in 2025, afterwards with a production of electric motors exceeding combustion ones’.
«Some years ago – stated Yann Vincent, executive vice-president and industrial director of PSA – we decided investing in the energy transition and making our plants more flexible. Trémery factory is an excellent example of this change».
If on one hand the environment is very grateful, on the other hand much concern regards employment, which might be reduced owing to the minor labour needed for an electric motor versus a conventional one.

Supply chain. Provisioning problems and price increases

Editorial Staff

The automotive production chain is sounding an alarm on the provisioning difficulties that, since the beginning of the year, it has perceived concerning stainless steel materials, plastic materials and microprocessors of vehicles’ electronic components. A strong rise in prices has been surveyed for steel and plastic materials since the start of 2021.
Referring to microprocessors, the missing offer on the market has already compelled various vehicle manufacturers and tier 1 suppliers to the manufacturing stop in some plants in Europe. If this circumstance should last, the risk of a negative impact on the European automotive supply chain in terms of employment is very high and would be summed to the criticalities already in progress in this delicate phase of Covid-19 pandemic management. The scarce availability of materials, in fact, is dangerously extending delivery terms, in some cases even tripled, threatening companies’ capacity of satisfying customers’ final demands, with consequent delays and risking of causing relevant economic losses. However, what are the reasons? We hypothesize it can be due to the absorption of a vast part of the world availabilities of raw materials by China, the current unavailability of containers and the annulment, by logistic players, of new unit orders in the first haff of 2020.

Peugeot e-208 is electric car business of 2021

Editorial Staff

The sixth edition of the Business Trophies 2021 took place in Paris. Nine Business trophies were at stake, for a total of 79 vehicles selected from among the novelties meeting the criteria for professional use in companies.
In the “Electric Business” category for 2021, the Peugeot e-208 won against 11 contenders with a total of 20 points and won the first prize.
But it isn’t the first time that ThePeugeot 208 winning. Indeed, it has already received 26 awards since its launch in October 2019, including the 2020 Car of the Year award. The new Peugeot 208 incorporates the brand’s latest stylistic codes with the innovative Peugeot i-Cockpit ® with 3D instrumentation, safe and aesthetic.
“We are very proud – said Hugues de Laage, B2B Sales Director France – that the Peugeot e-208 has been recognized as the best business electric vehicle of the year. The group’s product strategy on this multi-energy platform is rewarded and allows the PEUGEOT 208 to be recognized for its intrinsic qualities. We have the ambition to grow in volume after this year of full commercialization, the Peugeot e-208 has the best cost of use in its category and we must continue to progress to gain market share with the Peugeot e-208 higher than that of the Peugeot 208 in combustion engine».

What Modul-System as conversion partner?

Editorial Staff

Levc, London Electric Vehicle Company, has announced its first official conversion partner for its new VN5 electric van. It’s Modul-System, the largest global vehicle racking manufacturers that will support Levc across multiple key European markets.
Modul-System has been operating for over 40 years and offers high quality, custom and lightweight vehicle racking solutions specifically designed to meet the demanding and ever-changing needs of the commercial vehicle market.
The company has already provided conversions for Levc’s VN5 prototype ‘trial fleet’ of converted TXs that are being used by a wide range of businesses including logistics giants Dpd and Royal Mail, as well as telecoms flagship, BT Group.
Modul-System has been operating for over 40 years and offers high quality, custom and lightweight vehicle racking solutions specifically designed to meet the demanding and ever-changing needs of the commercial vehicle market. The company has already provided conversions For Levc’s VN5 prototype ‘trial fleet’ of converted TXs that are being used by a wide range of businesses including logistics giants Dpd and Royal Mail, as well as telecoms flagship, BT Group.

Hypercar and integrated circuits

Editorial Staff

In the name of the highest possible performances, stands out the collaboration between Rimac, manufacturer of electric luxury vehicles, for its C_Two model and the component supplier Analog Devices.
The mission is achieving a more accurate management of the batteries intended for electric sports vehicles: using the precision integrated circuits offered by Analog Devices, the BMS (battery management system) developed by Rimac will exploit at best the capacity of batteries, supplying in continuous a very accurate measurement of the charge status and of other fundamental parameters.
BMS manages the battery charge and discharge and, besides, it supplies vital safety measures to protect the accumulator against eventual damages. One of the key elements for the battery pack is the balancing of the cell groups that work together to prevent the anticipated interruption of the charge process and a reduction of the accumulator service life.
Therefore, integrated battery management circuits by Analog Devices guarantee a safer vehicle operation and the autonomy maximisation and they are integrated into Rimac C_Two, an electric hypercar equipped with a powertrain able to supply 1,914 HP (1,408 kW) with 2,300 Nm of torque.
Its performances are very high: it reaches 415 Km/h and takes just 1.85 seconds from 0 to 100 Km/h, while 300 Km/h are reached in just 11.8 seconds. The battery pack is equipped with 120 kWh capacity and the autonomy reaches 550 Km according to the WLTP cycle.

Volkswagen, the electric model that will replace Passat

Editorial Staff

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The shift to electric of traditionally estate cars is a very strong signal of the neat direction the market is undertaking.
In the lapse of three years, in fact, Volkswagen ID.6 is likely to replace Volkswagen Passat.
The new Volkswagen ID.6, which will be 100% Made in Germany because produced in Emden factory, will have two bodywork variants: a sedan and a station wagon estate car. The new electric model will be equipped with 84 kWh-capacity battery that will provide around 700 km autonomy. One of the two variants will be provided with rear electric motor and the other with double motor to offer all-wheel drive. What about the recharge speed? ID.6 supports fast recharges up to 200 kW, permitting to obtain about 230 km of autonomy in just 10 minutes from a fast DC column.
Volkswagen Passat will be probably replaced by about 36 months, precisely when the official presentation of Volkswagen ID.6 is scheduled.