The concept of mobility is rapidly changing, with sustainable energy, carbon footprint reduction, and electrification driving the evolution. As a leading global mobility supplier whose enduring success is built upon unsurpassed quality, outstanding technology, and partnership, Schaeffler is dedicated to energizing the next generation with sustainable mobility solutions that satisfy customer demands.
The successful transformation of Schaeffler’s automotive business is evident from the fact that it secured $5 billion euros in order intake for e-mobility in 2022. Driving this success are Schaeffler’s products, technology, and people.
Schaeffler has worked to transform in products in three key areas: a mix of ICE, hybrid, and BEV powertrains to meet current and future customer needs; intelligent, safe and reliable chassis systems; and new mobility solutions geared towards a driverless future. Dedicated to a systems approach, Schaeffler innovations span from electronic propulsion systems to steer-by-wire systems to innovative bearing advancements.
The consumption and emissions targets of the future can be met through electrification of the powertrain. Schaeffler offers a full range of electrification options from 48-volt hybrids and plug-in hybrids to technologies for all-electric vehicles and alternative drives, such as key components for fuel cells. The company’s systems expertise makes it the ideal partner for customers evolving into the electrified future. Schaeffler predicts the global percentage of new electrified cars in the year 2030 will be 80 percent (40 percent all-electric and 40 percent hybrids).
The idea of a steer-by-wire system initially seems almost foolhardy, as the system eliminates the steering column and the mechanical connection between the steering wheel and the steering gear. But on further investigation, this type of system has a wide range of benefits, including advanced driver safety. Schaeffler leveraged its experience in mechatronic systems to develop its intelligent Rear Wheel Steering System and took its first step towards becoming a steering system supplier. This intelligent technology turns the rear wheels in the opposite direction to the front wheels, significantly reducing the turning radius and optimizes maneuverability in tight spaces. At higher speeds, it further improves handling by allowing the rear axle to turn in the same direction as the front axle, enhancing handling, stability, ride comfort, and improving vehicle safety.
Innovative bearing solutions play a key role in sustainable mobility by making powertrain and chassis systems more efficient. Schaeffler has developed an alternative to tapered roller wheel bearings – called the TriFinity wheel bearing. The TriFinity wheel bearing can reduce friction by 50 percent and increases stiffness by 33 percent compared to a tapered roller wheel bearing while maintaining the same package envelope. This innovative ball bearing design provides an alternative to tapered roller wheel bearings that didn’t exist prior to TriFinity.
Schaeffler has been leading the successful transformation in mobility and in the areas of digitalization and sustainability. The company has made significant investments in its U.S.-based operations to support growth in this sector. To that end, Schaeffler’s facility in Wooster, Ohio, represents its E-Mobility Center of Competence in the Americas, leading the region’s development of the next generation of powertrain solutions.
This facility, which recently celebrated its 45th anniversary, has transformed from a team of six employees assembling manual clutches into approximately 1,700 highly skilled employees pioneering motion for products like the e-axle, which is responsible for moving the entire electric vehicle, gearboxes, hybrid systems, batteries, and more. The Wooster facility is supported by Schaeffler’s Troy, Michigan competence center for chassis mechatronics and ultra-low friction bearings like TriFinity. The Troy center leverages decades of expertise in engine and chassis developments, now focusing on the next generation of technologies for these components and systems.
Schaeffler's nationally recognized apprenticeship program also helps the global supplier attract and cultivate top talent that it needs to drive its E-Mobility transformation. Schaeffler offers apprenticeship programs throughout the country, partnering with technical schools to offer a range of trades. The 3.5-year program consists of both classroom and on-the-job training with a high retention rate after graduation.
In addition to apprenticeship programs, Schaeffler has partnered with 30 universities in the Americas to grow its internship and co-op programs. The company recently also developed a unique collaborative partnership with The Ohio State University (OSU), launching its first North American Schaeffler Hub for Advanced Research (SHARE) program. Located on the OSU campus in Columbus, the collaborative program is dedicated to advancing energy storage technology by working with students and professors on solid state battery and fuel cell technology. Schaeffler has several successful SHARE programs in Europe and Asia, each with a distinct focus.
Additionally, the Schaeffler Academy has developed a variety of Fit4 qualification programs to support the required re- and upskilling of employees. The programs consist of modular training options with defined learning paths that consider the target groups’ different backgrounds and areas of experience. The ‘Fit4Mechatronics’ program currently offers more than 100 training courses providing research and development engineers with knowledge about mechatronics and electronics.
With a dedicated focus on the transformation of its products, technology, and people, Schaeffler is embracing disruptive change as it continues its mission of energizing the next generation of future mobility.
Patrick Lindemann is President of Transmission Systems & E-Mobility at Schaeffler.
We are heading toward self-driving cars quicker than anyone could have imagined just a few years ago. While it will clearly be some time before our highways are packed with driverless cars making their way to work, home, and parts beyond, there are glimpses of the future driving alongside us now.
It may be the Honda Civic self-aligned in the fast lane beside you, or the Ford Fusion Energi in your rear view mirror that stopped without driver assistance as traffic ground to a halt, then automatically paced your car as your lane began moving again. Or maybe the driver of the nearby Subaru Crosstrek Hybrid who misjudged how quickly traffic would stop, but escaped incident because of on-board systems that sensed a collision and automatically initiated emergency braking. And what about that Tesla Model S ahead that signaled and changed lanes seemingly on its own as its driver focused on something else?
These are real capabilities of vehicles on the road today. Not all models with autonomous technologies are ‘green’ cars, but assuredly many of them will be since there’s a natural convergence of autonomous driving technology and more efficient cars unfolding before us. This is only gathering momentum as a growing number of vehicles begin to feature systems like these.
Already, cars are increasingly equipped with an array of sensors, radar, and cameras to facilitate driver assistance systems that help deal with mundane chores like backing up safely and parallel parking. These same sensors and systems provide a foundation for even more sophisticated autonomous driving capabilities.
Several automakers are striving mightily to lead the field. Tesla is one of these, not only with the ability for its Model S to autonomously stay in its lane and with traffic flow, but automatically and safely change lanes with the flick of a turn signal when Autosteer is engaged. Cadillac is another with its upcoming Super Cruise.
Volvo is also at the forefront of this race to an autonomous driving future, in part because autonomous cars are considered much safer ‘drivers’ than humans and this aligns well with Volvo’s ambitious goal to eliminate traffic fatalities in its vehicles by 2020. Its XC90 plug-in hybrid already features some of the most advanced autonomous systems out there including Sensus Connect, Intersection Auto Brake, and Pilot Assist. Volvo has also created its Concept 26 autonomous driving interior for the XC90, the first such autonomous-focused concept interior built on a vehicle platform sold today. Volvo is taking a lead role in the world’s first large-scale autonomous driving pilot project that will find 100 self-driving Volvos negotiating everyday driving tasks on 30 miles of public roads around Gothenburg, Sweden.
The specter of life with self-driving cars presents its challenges, not the least of which is consumer distrust of such systems and the concern we will lose the driving enjoyment and sense of freedom that automobiles have brought us since their invention. While we may be in a new era that finds technology impacting most facets of daily life – with this technology increasingly making its way to our cars – the love of driving remains a priority for many.
This is supported by a recent Volvo survey in which a vast majority of those asked said autonomous car technology should respect the love of driving and, in fact, autonomous cars should include a steering wheel even if they are capable of driving themselves. At the same time, most felt that technology in autonomous cars would make their travel time more productive. In other words, we want these worlds to coexist. There’s a lot to read into that …perhaps from the driver’s seat at 65 mph, no?
For a decade, Green Car Journal has been recognizing vehicles that significantly raise the bar in environmental performance. With automakers stepping up to offer ever-more efficient and ‘greener’ vehicles in all classes, the magazine’s awards program has naturally expanded to include a greater number of awards for recognizing deserving vehicles.
This prompted the recent suite of Green Car Awards presented during Policy Day at the Washington Auto Show in the nation’s capital – the 2015 Green SUV of the Year™, 2015 Green Car Technology Award™, and 2015 Luxury Green Car of the Year™.
BMW’s gull-wing i8 earned the distinction as the 2015 Luxury Green Car of the Year, outshining competitors Audi A8 L TDI, Cadillac ELR, Porsche Panamera S E-Hybrid, and Tesla Model S. Aimed at aspirational buyers who value superb styling and exceptional performance combined with the efficiency of plug-in hybrid drive, the i8 is unique among its peers with an advanced carbon fiber passenger body shell. It also features a lightweight aluminum drive module with a gasoline engine, lithium-ion batteries, and electric motor. The i8 can drive on battery power for 22 miles and up to 310 miles on hybrid power.
The Jeep Grand Cherokee EcoDiesel rose to the top as the magazine’s 2015 Green SUV of the Year, besting finalists Honda CR-V, Hyundai Tucson Fuel Cell, Lexus NX 300h, and Mazda CX-5. Offering excellent fuel efficiency for an SUV of its size, the Grand Cherokee EcoDiesel’s 3.0-liter EcoDiesel V-6 offers up to 30 highway mpg and is approved for B20 biodiesel use. An Eco Mode optimizes the 8-speed transmission’s shift schedule, cuts fuel feed while coasting, and directs the air suspension system to lower the vehicle at speed for aerodynamic efficiency.
The Ford F-150 was honored with the 2015 Green Car Technology Award for its milestone use of an all-aluminum body. Competing for the award were advanced powertrains in the BMW i3, BMW i8, Chevrolet Impala Bi-Fuel, Ford F-150, Honda Fit, Kia Soul EV, Tesla Model S, VW e-Golf, and Volvo Drive-E models. The F-150’s aluminum body enables the all-new 2015 pickup model to shed up to 700 pounds for greater efficiency and performance.
While the Green Car Technology Award has a history at the Washington Auto Show, the first-time Green SUV of the Year and Luxury Green Car of the Year awards could not have existed just a short time ago. Simply, SUVs and luxury vehicles were seldom considered ‘green,’ and for good reason. An SUV/crossover’s mission was to provide family transport and recreational capabilities, while aspirational/luxury vehicles were expected to deliver the finest driving experience combined with high-end appointments and exceptional design. Both categories held few environmental champions and ‘green’ was hardly an afterthought.
The evolving nature of ‘green’ cars has brought about a fundamental shift in which environmental performance is now important in SUVs and luxury vehicles. Even so, not all models in these classes are created equal. The challenge has been finding the right balance – the ‘sweet spot’ – that finds SUVs and luxury vehicles delivering the efficiency and environmental qualities desired without sacrificing the conventional touchstones – quality, safety, luxury, value, performance and functionality – that consumers demand. This year’s winners of the 2015 Green Car Awards clearly achieve this balance.
Presenting these important awards at the Washington Auto Show is compelling considering its reputation as the ‘Policy Show,’ a result of the show’s proximity to Capitol Hill and the influence that Washington DC has in driving a more efficient generation of vehicles to market. The 2015 Washington Auto Show has also expanded in recent years, receiving accreditation from the Organisation Internationale des Constructeurs d'Automobiles (OICA) as one of the five top tier auto shows in America. This year’s Washington Auto Show featured more than 700 vehicles from over 42 domestic and import auto manufacturers, plus a Green Car Awards exhibit showcasing 15 finalist vehicles within the show’s Advanced Technology Superhighway exhibit area.
We are all enamored by the advanced technologies at work in vehicles today. And why wouldn’t we be? The incredibly efficient cars we have today, and the even more efficient models coming in the years ahead, are testament to a process that combines ingenuity, market competitiveness, and government mandate in bringing ever more efficient vehicles to our highways.
It’s been a long and evolutionary process. I remember clearly when PZEV (Partial Zero Emission Vehicle) technology was first introduced in the early 1990s, a breakthrough that brought near-zero tailpipe emissions from gasoline internal combustion engine vehicles. That move was led by Honda and Nissan, with others quickly following. Then there were the first hybrids – Honda’s Insight and Toyota’s Prius – that arrived on our shores at the end of that decade. Both technologies brought incredible operating efficiencies that drastically reduced a vehicle’s emissions, increased fuel economy to unexpected levels, or both.
Of course, there were first-generation battery electric vehicles in the mid-1990s that foretold what would become possible years later. That first foray into EV marketing was deemed by many a failure, yet it set the stage for the advanced and truly impressive EVs we have today. Those vehicles may not yet be cost-competitive with conventionally powered vehicles due to very high battery costs, but that doesn’t diminish the genius engineering that’s brought them to today’s highways.
Even conventionally-powered cars today are achieving fuel efficiency levels approaching that of more technologically complex hybrids. Who would have imagined popular cars getting 40 mpg or better, like the Dodge Dart, Chevy Cruze, Mazda3, Ford Fiesta, and many more in a field that’s growing ever larger each year?
VW and Audi have proven that clean diesel technology can also achieve 40+ mpg fuel efficiency while providing press-you-back-in-your-seat performance, and importantly, doing this while meeting 50 state emissions criteria. That’s saying something considering diesel has historically had a tough go of it meeting increasingly stringent emissions standards in California and elsewhere. Yet, with elegant engineering by these automakers and their diesel technology supplier Bosch – plus this country’s move to low-sulfur diesel fuel late last decade – ‘clean’ diesel was born.
I would be remiss if I didn’t mention natural gas vehicles. There was a time when quite a few automakers were exploring natural gas power in the U.S., but that faded and left Honda as the lone player in this market with its Civic Natural Gas sedan. Now others are joining in with dual-fuel natural gas pickups and vans, benefitting from advanced engine technologies, better natural gas tanks, and a sense that with increasing natural gas reserves in the U.S., demand for natural gas vehicles will grow. As Honda has shown with its Civic, it’s possible to operate on this alternative fuel while also netting admirable fuel efficiency.
All this advanced powertrain technology is important. It makes air quality and petroleum reduction goals achievable, even ones like the ethereal 54.5 mpg fleet fuel economy average requirement that looms for automakers by 2025. There’s no doubt that advanced technologies come at a cost and reaching a 54.5 mpg average will require the full range of efficiency technologies available, from better powerplants and transmissions to greater use of lightweight materials, aerodynamic design, and answers not yet apparent. But I’m betting we’ll get there in the most efficient way possible.
Ron Cogan is editor and publisher of Green Car Journal and editor of CarsOfChange.com