IAA 2021: Schaeffler presents optimized electric powertrains with 800-volt technology
Schaeffler is taking the next step in efficiency and sustainability at the IAA. In addition to efficient bearing and damping solutions for hybrid transmissions, the company is presenting a new 800-volt power electronics system for e-axle systems and a highly integrated thermal management system. Matthias Zink, CEO of Automotive Technologies at Schaeffler AG, explains:
“Our decades of expertise in internal combustion engine drives form the foundation for shaping change in e-mobility that moves the world. Numerous series nominations in the field of electrified drives prove that Schaeffler is on the right track.”
In the first half of 2021, the order intake volume in the e-mobility division reached 2.1 billion euros, already meeting the target set for the entire year 2021. Dr. Jochen Schröder, Head of the E-Mobility Division, is aiming even higher:
“From 2022, an annual order intake of two to three billion euros is planned in the e-mobility division.”
A new high-voltage power electronics system expands the product portfolio
Schaeffler is unveiling a proprietary 800-volt power electronics system for applications in e-axles of high-performance vehicles. The scalable solution enables continuous power outputs of up to 330 kW and short-term peak outputs of up to 500 kW. The realizable power density of up to 70 kW per liter means small housing dimensions and therefore advantages in integration. In addition to the motor, the power electronics make a significant contribution to the efficiency of a drivetrain. Schaeffler relies on the latest wide-bandgap silicon carbide technology in the 800-volt onboard network. This significantly reduces power loss compared to conventional silicon IGBT technology and enables efficiencies of over 99 percent in defined load ranges. This significantly increases the overall range of electric vehicles. Furthermore, the 800-volt voltage class allows significantly higher charging speeds than the previously widespread 400-volt voltage class. The solution also uses Schaeffler's own motor control system, which enables various modulation methods and variable switching frequencies.
Highly integrated 3in1 e-axle
Schaeffler demonstrates how the power electronics harmonize in an overall system with its 3in1 e-axle, which combines an e-motor, transmission, and power electronics in one system. Schaeffler’s proprietary software handles the signal processing and control of the drive. The performance e-axle from Schaeffler impresses with an outstanding torque density of the transmission and is characterized by compactness, high power density, high system efficiency, and excellent acoustic behavior. With a modular design, the system can meet different usage requirements and be applied to various vehicle platforms.
Thermal Management in a Single System for the First Time
To achieve high efficiency, Schaeffler's thermal management system continuously and adaptively regulates the temperature in response to environmental and operating conditions—particularly that of the battery, but also of the electric motor and power electronics. In addition, the system also regulates the temperature within the vehicle cabin while ensuring maximum vehicle range. The central control unit for coolant and refrigerant integrates two electric water pumps, the central electronic unit for the pumps and valves, and a refrigerant circuit interface. This reduces the space requirement by up to 60 percent compared to conventional, non-integrated systems, while its hydraulically optimized design lays the foundation for the high overall efficiency of the system.
What does this mean?
Schaeffler is once again making a big splash at the IAA 2021: Especially the new 800-volt power electronics are making headlines.
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