Schaeffler launches 4-in-1 electric axle drive system to save space and weight/reduce energy consumption

According to foreign media reports, at the ElectricVehicle Symposiumin Oslo, Norway , automotive supplier Schaeffler demonstrated a series of electric drive solutions, including a four-in-one electric axle drive.system.Currently, the system is still under development and is said to be Schaeffler's most comprehensive electric vehicle drive system to date.

(Image credit: Schaeffler)

In addition to the motor, power electronics and transmission components (often integrated within the same package), the 4-in-1 system also includes thermal management components.According to Schaeffler, the highly integrated approach aims to save space and weight.In addition, the thermal management system is highly effective, helping to extend the electric vehicle's range on a single charge and to speed up charging.With this drive system, it is possible to reduce energy consumption by about 14%, because the waste heat is used and benefits from the new CO2 heat pump.

As we all know, thermal management of the entire electric drive system is very important.Heat is a "scarce and precious thing" in electric vehicles because there is no waste heat from the internal combustion engine, and the drive system is highly efficient.Among other uses, heat is needed to heat internal structures or batteries to optimize range and speed up charging.If there is no heat available, the battery must be drained, thereby increasing energy consumption.Jochen Schröder, Head of Schaeffler's Electric Drives business unit, said: "Thermal management system has a great influence on the efficiency and comfort of the car." With the four-in-one electric axle, "a highly integrated and compact complete system is created, which is compatible with non- Compared to an integrated solution, much less space is required.”

Less energy is lost in the form of heat as unnecessary hoses and cables are eliminated."Besides the compact design, the biggest advantage of this 4-in-1 system is the optimization of the interaction between the individual subsystems," says Schröder. Engineers take into account the thermal behavior of individual drive components, such as electric motors or power electronics, when developing equipment is also considered to fully enhance the overall efficiency and thermal management of the vehicle.For example, instead of using heat sinks to dissipate waste heat from motors and power electronics, this heat is used to heat internal structures.

According to Schröder, this will help reduce development time and save costs on developing the overall drive system.Both established car manufacturers and start-ups are the target group for such highly integrated drive units.

In addition to highly integrated units, Schaeffler will continue to offer users individual components or subsystems, including driveshafts with two or three subsystems.With a broad product portfolio, Schaeffler hopes to serve markets such as passenger cars and light commercial vehicles.

Also new is an electric rigid axle for pickups, the so-called Beam electric axle.The unique feature of this 3-in-1 system (motor, power electronics, drive) is that it can be up to 2 meters wide.Schaeffler will supply these products to automakers, especially in North America.