Schaeffler showcased a compact, highly integrated generator module for range extender electric vehicles (REEVs), new high-performance master control units designed for software-defined vehicles, and ongoing work on thermal management solutions using PFAS-free refrigerants at the CTI Symposium in Berlin.
The new range extender module targets REEVs—vehicles gaining momentum in China and the US for applications that require extended driving range. Schaeffler says that the module combines an electric motor and power electronics, an integrated cooling system with oil pump, water connection and oil filter within a compact form factor. The Power Class 2 version delivers up to 300 kW of continuous charging power, directly providing energy to the battery and sufficient for towing pickup trucks with trailers. The range extender comes in 400 V and 800 V variants and operates when battery levels drop below a defined threshold. The smaller 80 kW module achieves an axial length under 200 mm, facilitating installation alongside an internal combustion engine and generator within EV powertrains.
Schaeffler’s new High Performance Master Control Unit (HP MCU) for software-defined vehicles. The HP MCU, built on the Aurix T4x micro-controller family and optionally the S32 system-on-chip, follows a modular and scalable platform approach. Schaeffler says this unit as a central integration platform for all powertrain functions, intended to improve real-time control and enable more efficient orchestration of EV components.
Schaeffler also showed its VoltShield-P insulation bearing for electric motors. This solution is designed to prevent bearing damage from high-frequency circulating currents. The company also highlights ongoing development of thermal management systems compatible with PFAS-free refrigerants, including propane and carbon dioxide, to address evolving environmental regulations and operational requirements.
Schaeffler notes its product lineup is modular across mechanical, electronic and mechatronic components, and encompasses solutions for battery-electric vehicles, all hybrid configurations and REEV architectures.
“Thanks to its product range and innovative strength, Schaeffler is carving out a defining role in the e-mobility segment, because we really do cover everything, from mechanical components, modules and complete systems to solutions for modern vehicle electrical architectures with centralized software for the software-defined vehicle,” said Thomas Stierle, CEO E-Mobility at Schaeffler.
Source: Schaeffler
Topics: Schaeffler, Electric Powertrains, Electric Motors, Power Electronics, EV Control Systems, Thermal Management
