Schaeffler on the evolution of electric drives for EVs

Battery technology grabs most of the limelight and publicity when it comes to advances in electric vehicle technology.

But, without an electric drive, the vehicle will not move. The more efficient the drive, the further it will go on a single charge.

André Metzner, SVP Business Division E-Drives & E-Mobility Europe at Schaeffler, emphasizes the drive’s role in shaping the future of electromobility. Schaeffler offers advanced electric axle systems, e-motors, and hybrid solutions, earning global recognition for their expertise in both individual components and complete systems.

At IAA MOBILITY 2025, following the acquisition of Vitesco Technologies, Schaeffler introduced a broader, more customized product lineup.

Metzner says the integration enables tailored solutions for various market segments, using modular platforms and technologies like PSM and EESM motors, silicon and silicon carbide components, and diverse gearbox configurations.

In June 2025, Schaeffler reached a milestone by producing 100,000 EMR4 axle drives in South Korea. The company continues to innovate with new high-density drives, mobility service solutions, and leadership in coaxial e-axle gearboxes.

Ongoing advancements target improved cost efficiency, greater functional integration, and new e-drive designs to reinforce Schaeffler’s position as a leading system supplier.

Technology showcased by Schaeffler included:

EMR4 electric axle drive

By 2035, battery-powered electric vehicles are expected to be the dominant drive technology. To meet this demand, Schaeffler is developing and manufacturing a wide range of electromobility solutions – from individual components such as electric motors, power electronics, and thermal management modules to complex high-voltage axle drives and electronic control units.

The EMR4 (Electronics Motor Reducer, 4th generation) combines a permanent-magnet synchronous motor, power electronics, and transmission in a single compact housing. Its modular architecture allows for precise adaptation to a wide variety of vehicle concepts.

Standardized interfaces ensure maximum compatibility and simplify integration into the vehicle.

“The EMR4 platform is designed as a modular system, offering free configuration,” says Stierle. “Different inverter, reducer, rotor and stator, and housing variants enable us to deliver tailored solutions that meet the diverse performance and packaging requirements of our customers worldwide.”

A variant that operates without rare-earth magnets is also available. In addition to electric drive systems, thermal management is playing an increasingly greater role in improving overall powertrain efficiency. Adaptability to future regulatory requirements is another key factor, particularly when considering the use of alternative refrigerants such as R744 (CO₂) and R290 (propane).

Schaeffler’s broad, modular thermal management portfolio supports both natural refrigerants.

From PHEV to REEV

Schaeffler offers solutions for every hybrid architecture Hy­brid architectures such as plug-in hybrids, mild hybrids, and range extenders.

“Schaeffler provides the full range of solutions – from individual components to complete systems – for all hybrid topologies,” says Zink.

“Our dedicated hybrid transmission, for example, combines power electronics with smart hydraulics featuring integrated cooling, a clutch system, and a parking lock mechanism.”

This all-in-one solution is suitable for both full hybrids and plugin hybrids and can be operated in electric, serial, or parallel configurations. In serial mode, this flexibility allows the internal combustion engine to operate consistently at optimum efficiency.

Schaeffler demonstrated the technology at IAA MOBILITY with an internal combustion engine demonstrator developed specifically for hybrid applications.

It features innovative damper solutions and electromechanical camshaft phasing units designed to meet future NVH requirements and emission standards.

To further enhance emissions control when using decarbonized fuels, Schaeffler offers the Flex Fuel Sensor, which measures precision prior to injection.

Chassis technologies for automated driving

By 2035, one in ten vehicles produced is expected to be highly automated (Level 4), with a further 15% featuring partial automation (Level 3).

These advancements create new expectations and requirements for safety and comfort.

“Through innovative damper and steering systems, supported by dedicated software, we are already delivering solutions today,” says Zink.

“At the same time, we are advancing our steer-by-wire technologies, such as the force feedback function in the Hand Wheel Actuator (HWA).”

This Schaeffler solution combines a magnetorheological brake with an optimized BLDC motor to provide a precise steering feel while ensuring efficient energy use.

The combination significantly reduces the requirement for copper and rare earths compared to conventional steer-by-wire technologies.

At the same time, it paves the way for innovative forms of vehicle control such as joystick steering.

Software as the key to future vehicle platforms

With the movement toward the “software-defined vehicle,” software-based vehicle functions will be consolidated in the future into centralized and zonal controllers, resulting in a significant reduction in both the complexity of vehicle architectures and wiring effort.

Schaeffler is developing technologies that form the electronic backbone of these future architectures.

“One of the highlights at our booth was a visualization of a modern E/E platform that is scalable, powerful, and both function- and service oriented,” explains Stierle.

“Thanks to our many years of expertise in electronics and software, we can deliver not only innovative solutions, but also the corresponding services.”

Examples include Master Control Units (MCUs) and Zone Controller Units (ZCUs).

The Zone Controller serves as a versatile communications interface, managing, connecting, and supplying all types of control units, sensors, and actuators within a defined zone.

The MCU forms the heart of the E/E platform, processing data for lateral and longitudinal acceleration, thermal and energy management, driving and charging strategies, and by-wire systems.

Based on a microprocessor, the MCU supports the highest level of functional safety (ASIL-D) while ensuring secure communication.

“In this way, Schaeffler is contributing to the functional safety and efficiency of future vehicle architectures,” says Stierle.

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