European and U.S. Tier 1 suppliers: Electrification business trends

Strengthening of EV and HV products such as 48V systems, eMobility

2018/07/23

Summary

  This report focuses on the trends of electrification related businesses, mainly in Europe, among the major Tier 1 suppliers in Europe and the U.S. (during the 18 month timeframe from January 2017 to June 2018).

  Electrification initiatives are becoming more active in Europe among the major European and U.S. Tier 1 suppliers. These suppliers are announcing their own EV concept cars, in addition to powertrain and charging systems for hybrid vehicles (HV) and electric vehicles (EV). These suppliers are also developing new products, promoting partnerships with highly specialized companies in various fields, and acquiring start-up companies.

 

Tier 1 supplier electrification trends in Europe (Extract)

Bosch • Full-scale development of solutions to improve the convenience of EVs
• Announcement of the eAxle system that can be mounted on vehicles across a wide range of segments such as HVs, EVs, compact cars, SUVs, and light-duty commercial vehicles
• Developing the electric powertrain, incorporating eAxle, for Nikola’s hydrogen fuel cell Class 8 truck
• Released prototypes such as the "e.GO" four-seat compact car equipped with a 48V drive system
• Announced a new 48V battery for HV applications in markets around the world, with production scheduled to start in the second half of 2018
Continental • Investing an additional EUR 300 million in powertrain electrification projects by 2021
• Strengthened its 48V mild hybrid portfolio, with plans to start volume production of high-voltage drive products from 2019
• 48V belt-driven starter generator system is standard on Audi's new A8
• Announced the AllCharge system which turns the electric powertrain itself into a charger
• Developed EV charging systems for both cable and wireless charging, and for all types of current and voltage levels
ZF • Announced the "Vision Zero Vehicle" concept car equipped with a 150 kW electric axle drive system
• Announced its new eAMT electrified automated manual transmission
• Developed electrified products for commercial vehicles, including its CeTrax all-electric central drive for city buses
• Announced the series production of the "e.GO Mover", a low-cost electric minibus jointly developed with emerging EV automaker e.Go Mobile
Schaeffler • Established an electric mobility division in January 2018 to accelerate the development of HV and EV solutions
• Announced the new "Agenda 4 plus One" program to further its transformation process for the future, which includes initiatives such as E-Mobility
• Announced include the High Performance 48V concept car, E-Wheel Drive
• Announced technology concepts for future urban mobility solutions such as electric drives for HVs and EVs

 

Schaeffler’s E-Mobility products Magna’s electrification system and lightweight products

 


Related reports:
Top 30 global supplier rankings for FY 2017(Jun. 2018)
Electrification of powertrain products by major suppliers including BorgWarner (Jun. 2018)
JSAE Exposition 2018: CASE Technologies of System Suppliers (May. 2018)
European and U.S. Tier 1 China business: NEVs, autonomous driving, and connected cars(Apr. 2018)

 



Bosch: Promoting e-mobility, and the production of eAxle and 48V batteries

 Bosch established an operating unit specializing in e-mobility within its Powertrain Solutions Division, becoming operational from the beginning of 2018. Bosch also has begun full-scale development of solutions to improve the convenience of EVs. Bosch invests EUR 400 million annually in e-mobility, primarily in the research and development of battery technologies.

 Bosch announced its "eAxle" electric axle drive system that can be mounted on vehicles across a wide range of segments such as HVs, EVs, compact cars, SUVs, and light-duty commercial vehicles. Bosch will integrate eAxle into the powertrain of Nikola's hydrogen fuel cell Class 8 truck and jointly develop the fuel cell system with Nikola. Bosch also released prototypes of the "e.GO" four-seat compact car and the "Schwalbe-Rollers" electric scooter, both equipped with a 48V drive system.

 Bosch announced a new 48V battery for HV applications in markets around the world, with production scheduled to start in the second half of 2018, most likely for installation in the entry level HV models of Chinese automakers. On the downside, Bosch decided to withdraw from the in-house production of battery cells for electric vehicles and divest SEEO, its research and development subsidiary for solid-state battery technologies.

 

eMobility New department specializing in e-mobility, operational from the beginning of 2018
Bosch established an operating unit specializing in e-mobility within its Powertrain Solutions Division, becoming operational from the beginning of 2018. The Gasoline Systems and Diesel System divisions were combined to focus on the three segments of passenger cars and commercial vehicles equipped with internal combustion engines, HVs, and EVs. Bosch invests EUR 400 million annually in e-mobility, primarily in the research and development of battery technologies. To date, Bosch has received orders for more than 30 e-mobility related projects from automakers around the world. Approximately 1,800 employees are engaged in e-mobility projects. (From a press release on February 7, 2017)
Full-scale development of solutions to improve the convenience of EVs
Bosch has begun the full-scale development of solutions to improve the convenience of EVs. Bosch has developed technologies such as those that can provide EV range projections based on the usage situation and optimized route guidance that considers charging locations, as well as an energy management system that efficiently uses electricity between the EV and the home ("system!e"). Some of these technologies have already been commercialized in Europe. In the future, Bosch is planning to collaborate with non-automotive industry companies to realize services to make more effective use of a user’s time during rapid charging. (From an article in the Nikkan Jidosha Shimbun on June 25, 2018)
eAxle
48V Drive System
“eAxle” electric axle drive system
Bosch announced its eAxle electric axle drive system. eAxle is a modular platform that integrates the motor, power electronics, and transmission into one system, boosting energy efficiency, improving performance and reducing weight compared to the installation of each component separately. Compared with the case in which automakers use individual parts, costs can be reduced by 5-10%. eAxle can be mounted on vehicles across a wide range of segments such as HVs, EVs, compact cars, SUVs, and light-duty commercial vehicles. Production for the mass market is scheduled to start in 2019. (From a press release on January 10 and August 31, 2017, and an article in the Nikkan Jidosha Shimbun on September 19, 2017)
Bosch and Nikola developing an electric powertrain, incorporating eAxle, for a hydrogen fuel cell truck
Bosch and Nikola Motors announced that they will jointly develop an electric powertrain. Nikola will launch a Class 8 (Heavy duty: GVW 15 tons or more) hydrogen fuel cell truck by 2021, with both companies using their expertise to develop the eAxle system for the world's first dual motor powertrain for commercial vehicles. The two companies will jointly develop the fuel cell system to be combined with eAxle, as well as the control system that will be based on Bosch's vehicle control software and hardware. Furthermore, Bosch plans to provide powertrain systems for the Nikola product lineup, which will include the safety concept and vehicle electrical architecture. (From a press release on September 19, 2017)
Four-seat compact car e.GO, equipped with 48V drive system
As a compact EV mobility solution for crowded metropolises, Bosch released prototypes of the "e.GO" four-seat compact car and the "Schwalbe-Rollers" electric scooter. Both are equipped with a 48V drive system. The lithium-ion battery provides high energy density, and the charger is capable of quick-charging with ordinary household sockets. Operating modes can be selected via the display, and communication between the vehicle and the driver is facilitated via a Bluetooth interface and a dedicated software application. This system is comprised of off-the-shelf components, so it can be adopted to lower development costs. As a result, not only existing automakers, but also emerging automakers will be able to introduce products to market more quickly. The company predicts that 100 million units of electric scooters and small electric four-wheelers will be produced worldwide by 2020. (From a press release on July 4, 2017)
Battery Production of new 48V battery will start in late 2018
Bosch announced a new 48V battery for HV applications in markets around the world. Production of the battery is scheduled to start in the second half of 2018, most likely for installation in entry level HV models. Bosch plans to supply powertrain components in addition to 48V batteries. In particular, the demand from Chinese automakers for 48V batteries is increasing as a result of 48V hybrid systems equipped with fuel efficient boost recuperation systems (BRS). (From a press release on October 10, 2017)
SEEO, a Bosch research and development subsidiary for solid-state battery technology, is being divested withdraw from the in-house production of battery cells for electric vehicles
Bosch had considered the in-house production of battery cells for electric vehicles, but officially decided to cancel its plans. The company miscalculated in its expectation that the demand for electric vehicles would grow faster than previously anticipated as a result of strengthening global environmental regulations. Large investment amounts are required to compete with battery cell manufacturers with high market share. In addition, battery cells are expected to become a commodity product more quickly in the medium- to long-term when battery technologies are standardized. In consideration of the increased investment risks, Bosch decided to outsource battery cell production and withdraw from battery development and improvement research. For solid-state batteries, while recognizing its potential as a “future technology”, Bosch has decided to sell SEEO, its subsidiary that has been involved in the R&D of battery technologies. For reference, the company’s research results on battery cells collected over the years, including collaboration in a joint venture with GS Yuasa, will be utilized for products such as battery management systems, and 48V battery systems. In addition, Bosch says that several hundred employees are assigned to continue the preparation of the technical specifications for the battery cells. (From an article in the Nikkan Jidosha Shimbun on March 5, 2018)

 

Powertrain system for EVs 48V battery


Continental: 48V mild hybrid system, and systems such as AllCharge for EVs and HVs

  Continental will invest an additional EUR 300 million in powertrain electrification by 2021 for the research and development of products for its Hybrid Electric Vehicle (HEV) Business Unit. In 2025, the company plans to increase its market share of pure electric drive systems to 10% and its market share of hybrid systems to 30%.

 At exhibitions held from 2017 to the first half of 2018, Continental announced a number of new products in the field of electric mobility. Key products exhibited include:
• A 48-V mild hybrid system that is already in production
• High-voltage drives for EVs and HVs that will go into production in 2019
• Systems for all-electric vehicles such as a highly integrated electrical powertrain module

 In addition, Continental announced its "AllCharge" system as a solution to the problems posed by the non-standardized charging station infrastructure for EVs and which turns the electric powertrain itself into a ‘charger’. The system supports both cable and wireless charging including conventional on-board AC charging and DC charging at fast-charging stations. In addition to fully automated electromagnetic induction wireless charging, the AllCharge system also makes it possible to use EVs as a power grid-integrated mobile energy storage source.

 

Electric drive business Additional investment of EUR 0.3 billion in electric power business by 2021, focus on R&D of HV business
As part of its "Powertrain Strategy 2020+", Continental announced that it will invest an additional EUR 300 million in powertrain electrification by 2021. Continental has invested EUR 1 billion for powertrain electrification over the past five years. The company says that its HEV Business Unit is expected to grow, with sales increasing from the current EUR 130 million to EUR 1 billion by 2020 or 2021, and EUR 2 billion by 2025. In 2025, the company plans to increase its market share of pure electric drive systems to 10% and its market share of hybrid systems to 30%. The combination of internal combustion engines with electrified systems will continue, but Continental does not expect a decline in hybrid systems even beyond 2025. (From a press release on April 25, 2017)
EV and HV systems Starting production of high-voltage powertrain products from 2019
Continental announced that it has developed systems for all-electric vehicles such as a highly integrated electrical powertrain module, and high-voltage drives for 48V mild hybrid systems, EVs, and HVs. The 48V system can be equipped in both gasoline engine and diesel engine powered vehicles, and improves fuel economy by around 21% in real-world urban traffic conditions. The high-voltage powertrain products will go into production from 2019. In addition, the company announced products such as its AllCharge system that allows vehicles to use any EV charging station and its new lightweight wheel and brake design called the "New Wheel Concept". Continental’s hose development department has developed cables for EVs that maximize the service life of EV batteries. (From a press release on June 19 and September 5, 2017)
48V belt-driven starter generator system is standard on Audi's new A8
Continental announced that its 48V belt-driven starter generator system will be equipped as standard on Audi's new A8. The system has a continuous power rating in generator mode of up to 5 kW and a peak output of 15 kW available for short periods. The combination of pure EV driving mode, idling stop, and improved regenerative braking performance results in fuel savings of up to 0.7 L/100 km. The system has been in production at Continental’s Nuremberg Plant in Germany since 2017. (From a press release on January 15, 2018)
AllCharge AllCharge system utilizes the electric powertrain as a charger
Continental released the "AllCharge" system as a solution to the problems posed by the non-standardized charging station infrastructure for EVs. Rather than cramming the car with extra technology to match all the different types of charging stations, Continental has integrated all of the components required for charging into the AllCharge system to turn the electric powertrain itself into a ‘charger’. This makes it possible to provide interoperability with different charging technologies using an onboard, vehicle-based solution. (From a press release on May 29, 2017)
Development of EV charging systems for all types of voltage and current levels
Continental announced that it has developed the AllCharge system, a comprehensive portfolio of scalable, globally compatible EV charging products. The portfolio includes systems for both cable and wireless charging, and for all types of voltage and current levels. The AllCharge system also makes it possible to use EVs as a power grid-integrated mobile energy storage source. (From a press release on October 8, 2017)
Electromagnetic induction wireless charging system
At CES 2018 Continental exhibited a wireless charging system that uses electromagnetic induction technology. The system adopts a micro-navigation solution that allows the vehicle to be accurately positioned over the ground-based charging pad. (From a press release on January 8, 2018)

 

48V technologies AllCharge system


ZF: Promoting platforms for automated EVs and the electrification of commercial vehicles

 ZF announced a concept car equipped with a 150 kW electric axle drive system that can be used to achieve its vision of zero accidents and zero emissions. ZF is also developing electric micromobility products through its joint venture with three German motorcycle parts suppliers. ZF will provide its Intelligent Dynamic Driving Chassis (IDDC), a versatile platform for autonomous electric vehicles, for Rinspeed's latest urban mobility concept, “Snap”. ZF also announced its “eAMT” electrified automated manual transmission technology.

 ZF has announced a number of electrified systems for commercial vehicle applications.
• The CeTrax all-electric central drive for city buses
• The AVE 130 electric axle
• The "TraXon Hybrid" module for heavy-duty commercial vehicles
• Central axle drive for mini buses

 ZF agreed to a strategic cooperation alliance with ZAPI of Italy to offer electric and hybrid drive systems for trucks and buses. In addition, ZF and Germany's emerging EV automaker e.Go Mobile announced the series production of the e.GO Mover, a low-cost electric minibus for urban mobility jointly developed by the two companies that is scheduled to go into production in 2019.

 

Development of small electric cars Started joint venture with 3 suppliers to develop small electric cars
ZF launched a joint venture with three suppliers of technologies and services for motorcycle parts and batteries to develop small electric cars. The JV will begin the development, manufacturing and sales of electric micro-sized mobility solutions, which are expected to be enjoy increased market demand as a means of urban transport for people and cargo. ZF’s joint venture partners are Magura and BrakeForceOne, which manufactures motorcycle parts, and Unicorn Energy, a battery maker. Zukunft Ventures GmbH, which was established by ZF in September 2016, will make a 48% investment, becoming a leading shareholder in the JV. (From an article in the Nikkan Jidosha Shimbun on June 21, 2017)
Electrified systems "Vision Zero Vehicle" concept car with 150 kW electric axle drive system
ZF announced its Vision Zero Vehicle concept car equipped with state-of-the-art technology, featuring a 150 kW electric axle drive system. The drive system with integrated power electronics is housed in its space-saving mSTARS (modular Semi-Trailing Arm Rear Suspension) rear axle system. mSTARS makes it easier to electrify volume production vehicle platforms. (From a press release on June 21, 2017)
Provided to general-purpose platform for automatic operation EV "IDDC", Rinspeed "Snap"
ZF announced that it will provide its Intelligent Dynamic Driving Chassis (IDDC), a versatile platform for autonomous electric vehicles, for Rinspeed's latest urban mobility concept, Snap. The IDDC consists of its mSTARS rear axle system mSTARS as its core, environmental sensors, intelligent control units, and connected mechanical systems. The EasyTurn front axle enables a steering angle of up to 75 degrees. The rear axle is equipped active kinematics control (AKC) steering, which achieves a maximum steering angle of 14 degrees. (From a press release on December 20, 2017)
Electrified automated manual transmission "eAMT"
ZF announced its eAMT electric automated manual transmission, which integrates its eVD electric axle drive system and its automatic manual transmission (AMT) into one system. With eAMT, ZF says that automakers will be able to equip existing platforms with plug-in hybrid systems. (From a press release on June 18, 2018)
Development of electrified products for commercial vehicles ZF announced the following electrified products for commercial vehicles:
1) CeTrax: An all-electric central drive (drive axle located at the center of a bus) developed for city buses and long-distance transport vehicles. CeTrax can be combined with single rear drive axles and conventional low-floor axles for mounting in low-entry buses and all types of low-floor buses.
2) AVE 130 electric portal axle*: Solution for low-floor city buses. The axle allows for greater flexibility in the design of open vehicle interiors to accommodate more passengers.
 *The axle housing was redesigned to increase ground clearance by integrating the gears connecting the axle and drive shaft.
3) TraXon Hybrid: An electric motor module installed between the internal combustion engine and the transmission for heavy-duty commercial vehicles.
4) Central axle drive for minibuses: The product will go into production for passenger cars in 2018. It combines an electric motor with a two-stage single-speed transmission, differential and power electronics to form a highly-integrated, extremely compact unit. The system’s maximum output performance of 150 kW is sufficient for the power requirements of minibuses. In addition, ZF announced its ZF-EcoLife 6-speed AT with idling stop for city buses and the ZF-EcoLife Coach version for long-distance buses. (From a press release on May 23 and October 20, 2017)
Systems to simplify the transition to electrified-powered city buses
ZF is offering its proven AVE 130 electric axle and the new CeTrax electric central drive for city buses. The AVE 130 can be combined with most conventional power sources such as batteries, supercapacitors, fuel cells and overhead lines, and is suitable for series hybrid and plug-in hybrid applications. CeTrax was designed for low-floor and high-floor buses using a plug-and-drive approach, so it can be integrated into existing vehicle platforms without having to make major changes to the chassis, axles, and differentials. In addition, the TraXon Hybrid electric motor module installed between the engine and the transmission allows the hybridization of heavy-duty commercial vehicles. In generator mode the module can be used to supply power to other equipment such as the cooling units used for refrigerated delivery trucks. (From a press release on June 21, 2018)
Partnerships to electrify commercial vehicles Strategic cooperation alliance with ZAPI of Italy, providing EV and HV systems for trucks and buses
ZF has agreed to a strategic cooperation alliance with ZAPI of Italy. The aim of the cooperation is to offer customers commercial vehicle and industrial technology faster and more tailored complete electric or hybrid drive systems for applications such as trucks, buses, construction and agricultural machinery. The two companies will combine their expertise to accelerate the development of new drivetrains. ZF contributes its expertise in system design and mechanical components such as transmissions, axles, and steering systems. ZF's electric drive products in volume production segments are supplemented by ZAPI with electric components such as electric motors, inverters, and inverters for alternating current motors. (From a press release on November 12, 2017)
Series production of a low-cost electric minibus jointly developed with emerging EV automaker e.Go Mobile
Germany's emerging EV automaker e.Go Mobile announced the series production of its e.GO Mover low-cost electric minibus for urban mobility jointly developed with ZF. The vehicle is scheduled to go into production for the mass market in 2019. The E.GO Mover is about the size of an SUV and can seat up to 15 people. The vehicle can be used for on-demand bus mobility services and is reasonable priced, starting from about EUR 60,000 (approx. JPY 8 million). It can operate in city areas for up to 10 hours and can be equipped with a range extender operation to extend the range. e.GO Mobile's digital business division, e.GO Digital, is responsible for database service development for the e.GO Mover. This solution uses Microsoft's Azure cloud platform to optimize the development of user-oriented applications. (From a press release on April 25, 2018)

 

“mSTARS” rear axle system “EsyTurn” front axle


Schaeffler: Newly established electric mobility division, announcements of EV and HV concepts

  Effective January 1, 2018, Schaeffler established an electric mobility division responsible for HV and EV solutions. In addition, the company has acquired Compact Dynamics, an electric motor supplier, with plans to bring the production of drive motors in-house from 2020.

 At exhibitions Schaeffler has announced a number of modular system solutions for electric vehicles such as the high voltage eAxle, a thermal management module, a 48V hybrid module, and E-Wheel Drive. Concept cars that Schaeffler has announced include the High Performance 48V concept car and, for the future of urban mobility, the Schaeffler Mover EV and a cargo variant of the Bio-Hybrid.

E-Mobility Established E-Mobility division in January 2018, accelerating the development of HV and EV solutions
Schaeffler established its E-Mobility division on January 1, 2018, pooling its technologies, products and system solutions for hybrid and electric vehicles. The new division is responsible for managing electric powertrain technologies such as electric axle to accelerate the development of electrification. The company plans to invest EUR 0.5 billion in the E-Mobility division and hire an additional 1,200 additional employees. Schaeffler has received eight volume production orders for its electric axle and hybrid module solutions. The company expects that its products and systems for hybrid and electric vehicles will account for at least 15% of its total automotive business sales in 2020. (From an article in the Nikkan Jidosha Shimbun on September 7, 2017, and a press release on August 24 and September 21, 2017)
New "Agenda 4 plus One" program consists of initiatives such as E-Mobility and Industry 4.0
Schaeffler announced the new Agenda 4 plus One program to further its transformation process for the future. The program is comprised of 20 initiatives such as E-Mobility, Industry 4.0, the "Factory for tomorrow", and Working Capital. The program is aimed at increasing revenues by EUR 300 million in 2020. For E-Mobility, Schaeffler has 8 volume production orders and 25 customer development projects that are currently underway. (From a press release on March 7, 2018)
HV and EV concept High Performance 48V concept car
Schaeffler exhibited the High Performance 48V concept car at NAIAS 2017. In this concept, an electric rear axle supplements the front axle drive which is comprised of an internal combustion engine and a belt-driven 48V starter generator. The electric motor and the associated power electronics are integrated into a single unit on the rear axle. The 20 kW of pure electric power is thus permanently available from the 48V axle drive, and produces a starting torque of up to 2,000 Nm. The 48V system facilitates improved environmental performance and driving performance such as emissions-free, pure electric driving up to 35 km/h in areas where traffic is restricted, with a top speed of up to 70 km/h.
Other products exhibited include E-Wheel Drive that saves space and can be used for new interior design concepts by packaging all of the key components such as the electric motor, power electronics, brakes, and cooling device inside the wheel rim (wheel hub drive). E-Wheel Drive was developed for the automated driving vehicles and taxis of the future that transport passengers in large cities over short distance. (From a press release on January 9, 2017)
Electric drives for HVs and EV concepts for urban mobility
At the Schaeffler Symposium in April 2018 the company introduced its latest technology for future mobility. The company exhibited components and system solutions that optimize the powertrain of cars powered by gasoline internal combustion engines, as well as electric drives for HVs, and new concepts for EVs. Schaeffler’s EV concepts for the future of urban mobility included the Schaeffler Mover and a cargo variant of the Bio-Hybrid as a compact, flexible, freely scalable platform featuring electric wheel hub drives, 90-degree steering, and a modular design. (From a press release on April 12, 2018)
Electrified systems eAxle with parallel axis and coaxial design
Schaeffler announced electric axle systems with a parallel axis and coaxial design. The systems can be configured on a modular basis according to customer requirements to accommodate the drive requirements of any vehicle such as those powered by internal combustion engines, HVs, and EVs. Schaeffler also announced a single-speed transmission concept generates a maximum torque of 400 Nm despite, with an axial space requirement of 150 millimeters. The planetary gear design concept can also be applied to parallel axis drives. (From a press release on April 25, 2018)
Developed a modular electric drivetrain system solution for HVs and EVs
Schaeffler announced that it relies on hybrid technologies using efficient internal combustion engines, pure electric drives, and an environmentally-friendly and sustainable view of the entire energy chain for the development of customized system solutions for electrified drivetrains. Schaeffler has developed a modular system solution for HVs and EVs using electric axles with single-speed ratio in a coaxial or parallel axis design. In addition, The two-speed axle developed by Schaeffler enables lateral dynamics to be improved using a torque vectoring component, which adjusts the distribution of the drive force of the main motor to the left and right wheels. The high-efficiency rotation of the motor makes it possible to extend range by about 6%. (From a press release on December 4, 2017)
Exhibited FAG flanged housing units for electric motors
At the Hannover Messe 2018 Schaeffler exhibited FAG flanged housing units for electric motors (FAG is a Schaeffler Group affiliated brand). The locating and non-locating rotor bearing support, lubricating system, seal, and housing are precisely matched to each other and delivered in a ready-to-fit unit. The FERS and FERB series can be equipped with various bearing types and are suitable for both horizontal and vertical mounting positions. The FKC design was developed for heavy-duty horizontal machines and is equipped with a radial spherical roller bearing. The forth design, the FKC, is intended for use in large vertical machines, is equipped with axial spherical roller bearings and a radial deep groove ball bearing. (From a press release on March 27, 2018)
CVT transmission with hybrid function
Schaeffler received the 2017 Supplier Innovation Award from the German Center of Automotive Management (CAM) in the “drives” category. Schaeffler was recognized for its CVT transmission with an integrated electric motor and hybrid function. The transmission is characterized by lower energy losses and a compact design, which increases design freedom and contributes to weight reduction. The CVT solution was developed vehicles for the B and C segments. (From a press release on May 5, 2017)
In-house production of drive motors Acquisition of all shares of electric motor supplier Compact Dynamics
Schaeffler acquired all outstanding shares of electric motor supplier Compact Dynamics. The two companies have collaborated in the past, with Schaeffler incorporating a 20 kW electric axle drive system in its recently developed 48V concept car using the 48V drive system produced by Compact Dynamics. (From a press release on February 16 and December 12, 2017)
In-house production of drive motors for electric vehicles from 2020
Schaeffler has begun the in-house production of motors for electric vehicles. Schaeffler will supply electric-powered systems using outsourced motors for the time being, and will start producing systems fitted with motors produced in-house from 2020. In 2016, Schaeffler decided to acquire electric motor manufacturer Compact Dynamics (CD). Combining its transmission technologies and CD's motor technologies, Schaeffler will develop competitive electric systems to meet the demand associated with the electrification of vehicles. (From an article in the Nikkan Jidosha Shimbun on November 28, 2017)

 

48V hybrid module Electric axle one speed coaxial


Mahle: Strengthening of e-mobility and thermal management businesses

 Mahle introduced a wide range of e-mobility technologies on the MEET (Mahle Efficient Electric Transport) 48V concept car for urban mobility. Mahle has acquired Nagares, a Spanish electronics company, to strengthen its e-mobility business.

 Also, Mahle announced that it has partnered with Faurecia to jointly develop interior thermal management technology for future mobility solutions. Mahle acquired Germany-based O-Flexx Technologies to strengthen its thermoelectric power business.

 

eMobility MEET (Mahle Efficient Electric Transport) 48V concept car for urban mobility
Mahle introduced a wide range of e-mobility technologies on the MEET (Mahle Efficient Electric Transport) 48V concept car for urban mobility, as well as thermal management solutions and a range extender for electric vehicles. The technical focus of MEET is on maximum energy efficiency. To account for journeys at higher speeds the system output of the demo cars was set to 28 kW allowing a voltage level of 48V. The Mahle IPM (Interior Permanent Magnet Synchronous Motor) traction drive is an extremely efficient combination of a synchronous motor with permanent magnets and integrated 48V electronics that provides maximum efficiency and dynamics in a wide speed range. (From a press release on August 3 and October 6, 2017)
Acquired electronics company Nagares of Spain, strengthening its e-mobility division
Mahle acquired Nagares, an electronics company in Spain. Nagares develops and manufactures a variety of products for the automotive industry, including control units and power electronics for electric auxiliary components and thermal management systems, as well as power converters for e-mobility solutions. Mahle is strengthening its competence in e-mobility products through acquisitions and will focus on offering systems solutions such as electric drives, auxiliary components, and thermal management. The Nagares development center in Valencia will operate under the name Mahle Electronics SA. The objective is to establish the company within the Mahle Group as a global competence center for its electronics business. (From a press release on March 15 and May 24, 2017)
Thermal Management Collaboration with Faurecia to jointly develop interior thermal management technologies for future mobility solutions
Mahle announced that it has partnered with Faurecia to jointly develop interior thermal management technology for future mobility solutions. The two companies will collaborate using Faurecia's expertise in interior systems technology and Mahle's holistic thermal management technology. The two companies have already identified several potential collaboration fields addressing topics such as air distribution, air conditioning integration solutions for electric vehicles and the mutual development of personalized thermal management for the cockpit of the future. (From a press release on October 10, 2017)
Acquired German O-Flexx Technologies to strengthen Mahle’s thermoelectric power business
The Mahle Group announced that it will acquire Germany-based O-Flexx Technologies to strengthen its thermoelectric power business. Thermoelectrics technology can be utilized to convert exhaust heat from an internal combustion engine into electrical energy, contributing to the generation of heating or cooling from electrical energy. Established in 2006, the startup company O-Flexx Technologies specializes in developing thermoelectric elements, which are used, for example, to heat up the cabins of electrified vehicles. (From a press release on February 13, 2017)

 

48V concept car “MEET” 48V twin power


Magna: Enhanced development and production of 48V products and lightweight parts

 Magna is working on the development and production of lightweight parts as well as 48V products. Magna has partnered with StartUs Insights to help create more and deeper connections with the startup community in Europe. The collaboration provides Magna with a strong competitive advantage, especially in sectors such as e-mobility, autonomous driving, sensor technology and additive manufacturing.

 

48V products New 48V transfer case
Magna announced its new 48V transfer case and other 48V products to help automakers meet increasingly stringent CO2 emissions and fuel economy regulations. Magna’s "etelligentDrive eDS 48V High Performance System" is one of the first mild-hybrid transfer cases available to automakers. In addition, it’s a four-wheel drive system that provides CO2 savings of up to 10% and better fuel efficiency compared to a two-wheel drive system for mild hybrids. (From a press release on June 14, 2018)
Production and development of lightweight parts New aluminum casting factory established in the U.K., supplying parts for Jaguar Land Rover
Magna announced that it has established a new aluminum casting facility in Telford, England. The new facility will use Magna’s patented vacuum die-casting process to manufacture products for Jaguar Land Rover. The advanced lightweight aluminum castings help maximize strength and stiffness and minimize weight, which improves fuel economy, safety and handling. As electrified and hybrid powertrains become more common in the automotive industry, high-pressure aluminum castings can be a key factor in reducing overall vehicle weight. (From a press release on May 8, 2018)
Established new center in Germany for the research and development of composite materials and technologies
Magna's new Composites Center of Excellence in Esslingen, Germany, aims to help European automakers meet increasingly stringent emissions requirements with lightweight structures and exterior components made of advanced materials. The center has a new 2,300-metric-ton Engel V-Duo press that is ideally suited for thermoset compression molding of reinforced plastic or sheet molding compound materials. The Center will primarily focus on developing structural components, such as vehicle sub-frames, and exterior body parts, such as door panels and hoods. Several European automakers are pursuing joint development projects with Magna at the new center. (From a press release on March 7, 2018)
Collaboration with startup companies Partnership with StartUs Insights, and enhancement of capabilities in e-mobility, automated driving, and sensor technologies
Magna announced that it has partnered with StartUs Insights to help create more and deeper connections with the startup community in Europe. StartUs Insights is an innovation network that connects the European startup community and makes it accessible to its partners. In addition, kicking off the partnership is the Driving the Future of Mobility challenge, a competition for startups and innovators shaping the transportation industry. Collaboration with innovative startups is a key objective in Magna’s open for business approach. It provides the company with a strong competitive advantage, especially in sectors such as e-mobility, autonomous driving, sensor technology and additive manufacturing. (From a press release on September 28, 2017)

 

48V eAxle Composite material molded parts
Nissan Rogue lift gate


Valeo: Development of 48V systems and HVAC related products

 Valeo released an HV concept car equipped with a 48V system. The company is fully leveraging HVAC technologies to develop products such as battery coolers and heat pumps.

 

48V System 48V low-voltage motor control system for EVs and HVs
Valeo unveiled a 48V low-voltage motor control system for EVs at CES 2018. The system is 20% more economical than the existing high-voltage solutions, giving a small 2-passenger EV a range 100 km with a maximum speed of 100 km/h, making it ideally suited to urban driving. At the Viva Technology event in Paris, Valeo unveiled world's first rechargeable HV running at low voltage (48V). The new solution, installed in a five-passenger vehicle, can travel over 30 km in all-electric mode, with the internal combustion engine taking over for longer trips. (From a press release on January 8 and May 22, 2018)
HVAC Technology HVAC products for electric and hybrid buses
At Busworld 2017 in Belgium, Valeo presented its HVAC (heating, ventilation, air conditioning) solutions for electric and hybrid buses. Valeo displayed the REVO-E Global range of electric roof units that optimize the HVAC performance inside the cabin, the Battery Cooler system that maintains the cells in hybrid and electric vehicles for optimal longevity and performance, and the Heat Pump that is environmentally friendly as it does not use chemical refrigerants. (From a press release on October 19, 2017)
Heat pump not using chemical refrigerant, extending the range of EVs in cold climates
At the IAA Frankfurt 2017 Valeo unveiled a heat pump that does not use chemical refrigerants that can extend the range of electric vehicles by nearly 30% in cold climates. (From a press release on September 12, 2017)

 

48V electric rear axle drive (eRAD) New refrigerant heat pump system


BorgWarner: Enhancement of 48V system business, and electric motors adopting proprietary wire winding technology

 BorgWarner strengthened its 48V systems business, supplying product to Daimler and other automakers. Its proprietary wire winding technology has been adopted for electric motors.

 

48V System Supplying 48V mild hybrid systems for Daimler's 3.0L gasoline engines
BorgWarner announced that it will supply its 48V mild hybrid system for Daimler's 3.0L gasoline engine and to three other major automakers. The system consists of components such as the eBooster electric compressor and the iBAS integrated belt alternator starter. BorgWarner has stated that fuel efficiency can be enhanced 20% depending on the combination of the base engine and application. The company acquired Remy International, Inc. in 2015, and also decided to acquire Sevcon, Inc., an electrified vehicle parts supplier, by the end of 2017, aiming to strengthen its 48-volt mild hybrid system business. (From an article in the Nikkan Jidosha Shimbun on October 16, 2017)
Acquired Sevcon of the U.K. to offer products such as motor controllers for EVs and HVs
BorgWarner acquired Sevcon of the U.K., a global supplier of zero emissions solutions such as motor controllers for EVs and HVs. Sevcon’s Bassi Division produces battery chargers for electric vehicles, uninterrupted power source systems, and electronic instrumentation for battery laboratories. (From a press release on July 17 and September 28, 2017)
Conducted cold weather testing of drive systems using a 48V power supply system
BorgWarner conducted cold weather testing of drive systems equipped with 48V power supply systems at the Arctic Drive Winter Test in Sweden. BorgWarner’s 48V drive systems provide enhanced vehicle dynamics and traction even under extreme Arctic conditions. Other solutions tested include the company’s P2 hybrid modules, the electric Rear Drive Module (eRDM) for P3-type hybrids, the 48V electric All-Wheel Drive (eAWD) system for P4-type hybrids and the next-generation e-hydraulic AWD coupling. (From a press release on March 26, 2018)
Electric motor High Voltage Hairpin (HVH) 410 electric motor adopted for Scania's hybrid bus
BorgWarner announced that its high voltage hairpin (HVH) 410 electric motor has been adopted for Scania’s “Citywide” hybrid bus for urban areas. Positioned between the clutch and gearbox in a P2 layout, the 650-volt electric motor drives the vehicle at low speeds when enough energy is available. The motor also charges the battery by generating power while braking or driving downhill. With their clean, quiet operation, HVH410 electric motors allow buses to operate in zero emission zones and noise-sensitive areas. BorgWarner’s HVH410 electric motors are available as fully housed motors or as rotor/stator assemblies. Their compact dimensions and individually customizable stack length, cooling, and winding configurations facilitate easy integration into almost all electric and hybrid applications. (From a press release on September 4, 2017)
High-voltage wire forming technology for electric motors and alternators
BorgWarner announced that Automotive News awarded it the prestigious 2018 PACE Award for its "S-wind" high-voltage wire forming process for electric motors and alternators. The game-changing manufacturing process enables high-volume production of high-voltage electric motors up to 350 volts. BorgWarner expects to launch the technology in a first-of-its-kind 300-volt S-wind motor for an on-axis P2 hybrid vehicle for a major global automaker in late 2019. (From a press release on April 10, 2018)

 

Electric drive module (eDM) Electric motor


Faurecia: Development of fuel cell stacks and hydrogen tanks

 Faurecia signed a five year agreement with the CEA (French Alternative Energies and Atomic Energy Commission) to collaborate in the field of fuel cell stack technology. Faurecia also acquired exclusive rights to the intellectual property and process know-how of STELIA Aerospace Composites to design, manufacture, and market high-pressure hydrogen tanks using carbon fibers for fuel cell vehicles.

 The company is also investing in startup companies such as Silicon Valley's Powersphyr (wireless charging solution) and France’s Enogia (high speed turbine).

 

Fuel cell stack
Fuel cell tank
Five year R&D program tie-up with the French government for fuel cell stack technologies
Faurecia signed a five year agreement with the CEA (French Alternative Energies and Atomic Energy Commission) to collaborate in the field of fuel cell stack technology. Faurecia will benefit from more than two decades of CEA research and expertise in fuel cell stacks and key components such as bipolar plates. Combined with Faurecia expertise in fluid dynamics and catalysis, the alliance will be able to develop, mass-produce and commercialize a high performance fuel cell stack that will meet auto industry expectations. (From a press release on September 13, 2017)
Exhibited high-pressure hydrogen storage system and fuel cell stack
At the 2018 Hannover Messe, Faurecia demonstrated fuel cell technology such as a high-pressure hydrogen storage system and fuel cell stack. (From a press release on April 19, 2018)
Acquired exclusive rights to use STELIA Aerospace Composites’ intellectual property for complex hydrogen tanks
Faurecia acquired exclusive rights to the intellectual property and process know-how of composite hydrogen tanks from STELIA Aerospace Composites. As a result, Faurecia is now able to design, manufacture, and market high-pressure hydrogen tanks made of carbon fiber composites for fuel cell vehicles. This acquisition complements the investment that Faurecia recently made in Ad-Venta, a specialist in pressure valves for efficient and safe hydrogen storage. (From a press release on May 15, 2017)
Investment in start-up companies Invested in US Powersphyr, acquiring wireless charging solution
Faurecia announced an investment in Powersphyr, a Silicon Valley start-up specializing in innovative wireless charging solutions for the automotive, consumer, and industrial markets. (From a press release on May 9, 2018)
Invested in Enogia of France, developing a hermetic, compact high-speed turbine that recovers heat and converts it to electricity
Faurecia announced an investment in French startup Enogia to enhance its expertise in energy recovery technology. Enogia is developing a hermetically-sealed, compact high-speed turbine that recovers heat and converts it to electricity. Faurecia stated that Enogia’s technology is suited to commercial vehicles, trucks, and high horsepower engines such as for marine transport and generators. (From a press release on March 16, 2018)

 

Fuel cell stack Fuel cell tank


Plastic Omnium: Strengthening of fuel cell system business with products such as hydrogen tanks

 Plastic Omnium has strengthened its design and production capabilities for products such as hydrogen tanks through acquisitions and the establishment of an advanced research center in the field of fuel cells.

 

Fuel Cell System Exhibited energy storage systems such as electronically controlled high-pressure hydrogen tanks
Plastic Omnium exhibited energy storage systems such as electronically controlled high-pressure hydrogen tanks at the Frankfurt Motor Show in 2017. The company established POCellTech, a new advanced research center in the field of hydrogen fuel cell batteries in Brussels, Belgium in 2016. (From a press release on May 22 and September 11, 2017)
Acquired two companies, Swiss Hydrogen and Optimum CPV, specializing in the field of electric propulsion by fuel cells
Plastic Omnium announced that it acquired two companies, Swiss Hydrogen and Optimum CPV, specializing in the field of electric propulsion by fuel cells. Swiss Hydrogen specializes in the design and production of solutions for the control of energy control in fuel cell systems dedicated to mobility. Optimum CPV, based in Belgium, specializes in the design and production of hydrogen storage tanks made of filament composites. The two companies will be integrated into the New Energies unit newly established within Storage and Propulsion division of Plastic Omnium Auto Inergy. (From a press release on December 21, 2017)

 

High-pressure hydrogen storage system Concept car


Freudenberg: Strengthening electric mobility business and developing battery related products

 Freudenberg has strengthened its electric mobility business, developing battery-related products using technology acquired in the development of conventional products such as seals and filters.

 

Electric mobility business Strengthening of energy and e-mobility businesses
Freudenberg announced that has strengthened its position in the energy and electric mobility sectors through an acquisition and a strategic investment. In early 2018 Freudenberg acquired portions of fuel cell manufacturer Elcore and its sister company Elcomax. In February of 2018 the company also acquired a minority stake in XALT Energy in the U.S. XALT Energy manufactures lithium-ion batteries for heavy-duty commercial vehicles. (From a press release on May 14, 2018)
Battery related products Development of products such as separators for lithium-ion batteries
Freudenberg announced innovative battery technologies, fuel cells and environmentally friendly solutions for combustion engines. The company has developed a separator for lithium-ion batteries that is more resistant to mechanical stress. Freudenberg also exhibited products such as gas diffusion membranes (GDL) that will contribute making this technology ready for volume production and lowering the cost of fuel cells, as well as filter concepts. (From a press release on September 12, 2017)
Development of seal for battery housings
Freudenberg announced that it has developed a seal for battery housings. The company developed its patented Profiles-to-Gasket (P2G) concept for production runs of up to 5,000 batteries per year. The new housing seal concept was developed based on the principle to realize the two basic functions "sealing" and "fixing". (From a press release on June 27, 2017)
Development of heat shield for lithium-ion batteries
Freudenberg announced that it has developed a heat shield for lithium-ion batteries. Heat shields between individual cells are designed so that the heat from a damaged cell remains insulated until it can be drained away. The heat shield has three key characteristics: First, the shield itself consists of a heat resistant material, a silicone-based elastomer; second, it slows the heat transfer between the cells with a waffle-like structure. Third, the shield is very thin, with a maximum thickness of just 1 mm. The loss of the existing energy density the shield’s use is hardly noticeable. (From a press release on May 22, 2018)

 


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Keywords
Bosch, Continental, ZF, Schaeffler, Mahle, Magna, Valeo, BorgWarner, Faurecia, Plastic Omnium, Freudenberg, Tier1, supplier, electrification, EV, HV, hybrid, eMobility, 48V, eAxle, motor, Li-ion battery, battery, fuel cell

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