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Patrick Lindemann, President of e-mobility at Schaeffler.
Patrick Lindemann, President of Transmission Systems & E-Mobility at Schaeffler.

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.

schaeffler fuel cell power for sustainable mobility.

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.

Technology Transformation

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 Ohio plant focuses on sustainable mobility.

People Transformation

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.

Schaeffler electronics.

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.

Steve Hornyak, chief commercial officer of BrightDrop.
Steve Hornyak, BrightDrop Chief Commercial Officer.

Perhaps the most well-known benefit of switching to an electric vehicle is the environmental impact due to the elimination of tailpipe emissions compared to an internal combustion engine (ICE) vehicle. But what isn’t as obvious is that they can also be less expensive over the operating lifecycle.

Why? For starters, we tend to focus on fuel prices, yet one thing that often gets overlooked is the reduced maintenance costs electric vehicles can offer. The U.S. Government's Office of Energy Efficiency and Renewable Energy estimates that scheduled maintenance costs for light-duty battery electric vehicles are about 6 cents per mile, compared to 10 cents per mile for a conventional vehicle. Someone buying a passenger car for private use is less likely to worry about maintenance, but for large fleet managers these cost savings can be meaningful over time.

Another costly issue for fleets is unscheduled repairs caused by breakdowns. According to the Deepview True Cost Second Owner Study by predictive analytics and data company We Predict, unplanned repair costs for electric commercial vans are on average 22 percent lower compared to internal combustion engine equivalents after three years on the road. The reason for this is that electric vehicles have fewer mechanical parts than internal combustion engine vehicles. This is significant because reductions in repairs also mean more time on the road for busy delivery fleets. In a world where downtime is death for fleets, keeping vehicles on the road is critical to meeting the ever-increasing demand for last-mile deliveries.

Charging BrightDrop electric delivery van.

Meanwhile, in March 2022, CNBC reported that diesel fuel was already costing over $5 (USD) per gallon nationally, with gasoline hitting $6 (USD) in some parts of the country. So there can be important fuel cost savings to be made for fleets that switch to electric vans. In fact, BrightDrop estimates fleet owners will save over $10,000 (USD) per vehicle per year in fuel and maintenance when switching to one of our Zevo 600 electric vans, compared to its diesel equivalent. Let’s take a closer look.

Fewer Moving Parts

Why do we expect electric vehicles will need less maintenance? Moving parts are a big part of it, because it’s the moving parts that most often encounter problems. Standard internal combustion engine vehicles usually have over 2,000 moving parts in the drivetrain, while electric vehicles tend only to have about 20. For example, a battery electric vehicle has no timing or fan belt and no alternator. Additionally, an electric vehicle also lacks many of the complex non-moving parts that often fail in internal combustion engines, such as oxygen sensors, spark plugs, and catalytic converters. A 2020 CarMD Vehicle Health Index assessment of the top 10 most popular car repairs in America found replacing a catalytic converter was the most common, while replacing an oxygen sensor came second. According to Forbes, only one of these top ten repairs could ever happen to an electric vehicle (and it was the cheapest to fix at $15). The lack of moving parts also means that repairs on electric vehicles can be less complicated.

Additionally, electric vehicles usually don’t use transmissions, meaning that the common (and expensive) issue of damage to gears is not an issue. Many electric vehicles also use regenerative braking to repurpose expended energy back into the batteries. In addition to electricity savings, regenerative braking can also increase the life (and therefore reduce spending on replacing) of conventional brake parts, due to minimal use. Finally, electric vehicles don’t use engine oil and, although they do use engine lubricants, these rarely require a refill or change.

BrightDrop is electrifying fleets for last mile delivery.

Advantages of Electrifying Fleets

Electric vehicles can be cheaper to maintain and repair than their ICE or diesel alternatives. They also can be kept on the road longer by reducing the frequency of unplanned repairs, as well as reducing the amount of labor that would otherwise be spent dealing with these problems. All of these benefits take time to accrue. They can only be realized if fleet managers take a ‘total cost of ownership’ perspective that considers all costs over the lifetime of a fleet.

Perhaps the biggest concern that electric vehicle buyers have is that the battery will degrade over time, ultimately requiring an expensive replacement. We believe that such concerns can be overhyped or misplaced. Battery range has improved markedly in recent years, and all BrightDrop vehicles adhere to or exceed federal regulations, which require that electric vehicle batteries are covered by warranty for a minimum of eight years or 100,000 miles, whichever comes first.

Now is the time to switch fleets to electric vans. It's an opportunity not only to help reduce vehicle emissions, but also to help realize potential cost savings.

Steve Hornyak is Chief Commercial Officer and Executive Director at BrightDrop

2018 Nissan LEAF makes North American debut

Amid all the hype and hope for electric vehicles, there are many assumptions being made by those who believe electrics will dominate the worldwide automotive landscape in future years. How much is this based in reality? No doubt, consumer acceptance will vary depending on specific markets. According to a recent study, Future of Electric Vehicles in Southeast Asia, up to one in three Southeast Asian drivers in the market for a new car would be open to buying an EV. Commissioned by Nissan and conducted by Frost & Sullivan, the study is said to illustrate the very strong propensity for electric vehicles in the region.

The research focused on Indonesia, Malaysia, the Philippines, Singapore, Thailand, and Vietnam. Among its findings are that 37% of prospective buyers would be willing to consider an EV as their next car. Of these, the study points to consumers in Indonesia, the Philippines, and Thailand as the most inclined to do so.

2018 Nissan LEAF makes North American debutInterestingly, two out of three surveyed said that safety was most important to them, followed by charging convenience. Cost was not identified as a factor in their decision making, and in fact many of those surveyed said they would be willing to pay more for an electric vehicle. Green Car Journal editors note that early electric vehicle studies in the U.S. at times came up with the same conclusion that buyers would be willing to pay more for an electric vehicle, but that has not materialized. In fact, subsidies are often a prime motivator in prompting an EV purchase or lease.

While a higher price wasn’t identified as an obstacle to EV sales, that doesn’t mean lower cost wouldn’t be a motivator. In the study, three in four respondents said they would consider an electric vehicle if taxes were waived, and other incentives would also sway consumer decisions to go electric including free parking, the ability for solo EV drivers to use priority lanes, and installing charging stations at apartment buildings.

2018 Nissan LEAF makes North American debut"Leapfrogging in electrification of mobility requires strong collaboration between public and private parties and a long-term approach tailored to each market's unique situation," points out Yutaka Sanada, regional senior vice president at Nissan. "Consumers in Southeast Asia have indicated that governments have a critical role to play in the promotion of electric vehicles."

Nissan has announced that its Nissan LEAF electric car will go on sale in Australia, Hong Kong, Malaysia, New Zealand, Singapore, South Korea, and Thailand during the next fiscal year.

Mission E Cross TurismoPorsche says it plans to invest more than $7 billion (six billion euro) in electrified vehicles over the next four years. As part of this, the automaker will be devoting some $600 million toward the development of is coming Mission E electric sports car and other electrified variants. About $1.25 billion will be dedicated to hybrid and electric powertrains for existing Porsche models

“We are doubling our expenditure on electromobility from around three billion euro to more than six billion euro”, said Oliver Blume, Chairman of the Executive Board of Porsche AG. “Alongside development of our models with combustion engines, we are setting an important course for the future with this decision.”

Porsche’s stunning battery electric Mission E sports car will boast an output of 600 horsepower and deliver quick 0-60 mph sprints in less than 3.5 seconds. Driving range is claimed to be over 300 miles between charges. It will be fast-charge capable.

In addition to its investment in electrification, Porsche will invest some $250 million on manufacturing sites and facilities plus an additional $850 million on smart mobility, charging infrastructure, and new technologies.

2017-green-car-awards-washingtonFor a decade now, Green Car Journal has been presenting its Green Car Awards™ at the Washington Auto Show to recognize environmental achievement in the auto industry. The magazine’s most recent press conference during the 2017 Washington Auto Show’s second Policy Day found automakers honored for their efforts in three important categories. Named 2017 Connected Green Car of the Year™ was the Mercedes-Benz C350e, while the 2017 Green SUV of the Year™ was awarded to the BMW X5 xDrive40e and the 2017 Luxury Green Car of the Year™ to Acura’s new NSX.

Along with the award winners, 2017 Connected Green Car of the Year™ finalists included the Audi A3 e-tron, Honda Civic, Tesla Model X, and Toyota Prius Prime. Also identified as 2017 Luxury Green Car of the Year™ finalists were the BMW 740e xDrive, Jaguar XE 20d, Mercedes-Benz S550e, and Range Rover Td6, with 2017 Green SUV of the Year finalists including the Honda CR-V, Mazda CX-9, Mercedes-Benz GLE550e, and Nissan Rogue Hybrid. All offered either plug-in, efficient diesel, or advanced internal combustion power and each featured admirable levels of environmental performance.

2017-connected-green-car-of-the-year-1The Mercedes-Benz C350e, Green Car Journal’s 2017 Connected Green Car of the Year, offers drivers the luxury and driving enjoyment expected of a premium sedan, with the added benefit of plug-in hybrid power. Its overall driving range of 410 miles means there are no compromises. An estimated 11 miles of zero-emission driving is provided on batteries at an EPA estimated 51 miles-per-gallon equivalent.

Drivers are well-connected with an on-board Wi-Fi hotspot and an array of advanced, connected features including location-based, real-time traffic information and route guidance. Driver assistance systems play a major role in the C320e with data from radar sensors and stereo cameras enabling autonomous and semi-autonomous features. Among its capabilities is helping avoid collisions with vehicles ahead and in cross traffic at intersections, even applying full emergency braking if needed. On board systems can maintain a set distance from a vehicle ahead, even in stop and go traffic. Steering inputs helps drivers stay in their lanes.

2017-green-suv-of-the-year-1Green Car Journal’s 2017 Green SUV of the Year, the BMW X5 xDrive40e iPerformance, combines the versatility and luxury of a full-size, five-passenger SUV with the driving confidence of intelligent all-wheel drive. It offers desired levels of functionality and convenience expected of a full-size SUV, while also addressing efficiency and use of electrification.

A 241 horsepower, 2.0- liter TwinPower turbo four-cylinder engine and 111 horsepower electric motor enabling this nearly 5,000 pound plug-in hybrid SUV to accelerate from 0-60 mph in under seven seconds. It can travel 14 miles under electric power alone with a total driving range of 540 miles. To enhance all-electric driving, intelligent connectivity constantly monitors all factors affecting range including traffic conditions, route profile, and driving. Route guidance functions include displaying public charging station locations on a navigation map.

2017-luxury-green-car-of-the-year-1Winning the 2017 Luxury Green Car of the Year was achieved in style by the all-new NSX hybrid supercar. Promising the luxury of carving the perfect turn, riding on race-inspired suspension, and the exhilaration of breathtaking acceleration, the Acura NSX delivers the ultimate driving experience while also somehow netting some 31 percent better city mpg than the previous generation.

The NSX champions aerodynamics, hybrid drive, and lightweight materials like carbon fiber, SMC fiberglass, aluminum, and high-strength steel. Its mid-engine, twin-turbocharged V-6 connects to a nine-speed dual-clutch transmission integrated with a rear electric motor, with two additional electric motors powering the front wheels. The car’s 573 total system horsepower propels it from 0-60 mph in just 2.9 seconds. In a word, this hybrid supercar is ‘thrilling.’

mark-wallace-mercedes-green-car-awardsWinners and finalists for these three Green Car Awards are proof positive that it is no longer good enough to design and build vehicles with style, quality, functionality, and performance. It is necessary to do all this while also delivering much more, taking into account the need for highly-evolved models with improved efficiency, lower environmental impact, greater safety, and ever-expanding ways of connecting our lives and our vehicles to one another.

Hosting these Green Car Awards in Washington DC is appropriate considering the policies, regulations, and incentives that have historically come out of Washington DC that play a significant role in influencing the success and direction of lower emission, more efficient advanced technology vehicles. With its status as the largest public show in Washington and its proximity to the halls of power in the nation’s capital, the Washington Auto show is also the logical venue in Washington DC to honor environmental achievement in the auto industry.