Automechanika Frankfurt 2024 Service solutions for electrified vehicles: Schaeffler Vehicle Lifetime Solutions offers what the industry needs

2024-09-09 | Frankfurt

• Schaeffler E-Axle RepSystem-M enables repair of the e-axle motor in the Hyundai Ioniq
• The proven Schaeffler E-Axle RepSystem-G is now also available for transmission repairs in e-axles for the Hyundai Ioniq.
• New repair solution for thermal management module as well as electric auxiliary water pumps, and INA FEAD kits for 48V applications

Climate-friendly mobility would be inconceivable without the widespread move to hybrid and electric drives. Schaeffler Vehicle Lifetime Solutions (VLS) is consistently driving forward the development of e-mobility solutions as as the number of electrified vehicles on the road continues to grow worldwide. The Schaeffler division already provides a wide range of products for electric vehicles to distributors and garages. The entire range will be showcased at Automechanika, including many new products.

The mobility ecosystem is changing, with the focus shifting increasingly toward digitization and e-mobility. Schaeffler Vehicle Lifetime Solutions has responded to this shift by pursuing a clear strategy: To remain one of the leading providers of vehicle repair and service solutions in the future, the core business will need to be strengthened and adapted to meet new requirements. The company is sharpening its focus on new technology, particularly in the context of electrified vehicles, which make up an increasing proportion of the vehicle population: According to the Schaeffler Group estimations, 80 percent of all newly registered vehicles worldwide will be electrically powered by 2030, with 40 percent comprising purely electric vehicles and 40 percent comprising hybrid vehicles.

Strategic acquisition: Vitesco
In the near future, the aftermarket will witness a sharp rise in demand for spare parts and repair solutions for these vehicles, necessitating the need for corresponding know-how and additional qualifications. Further growth of the portfolio is also anticipated, with Schaeffer setting the stage for even more products and solutions to be made available for the electrified powertrain through the integration of automotive supplier Vitesco Technologies. The independent vehicle service will benefit from the company’s integration with the Schaeffler Group in areas such as thermal management, hybrid modules, and integrated e-axles.

For electric vehicles: E-Axle RepSystem-G and -M
Although diagnostic and repair processes for electric vehicles may change, components will continue to wear and require repair. Schaeffler Vehicle Lifetime Solutions already offers a wide range of solutions in this area, including chassis components for 85 percent of all registered hybrid vehicles.

As experts in the electric powertrain, the Schaeffler division is also at the forefront when it comes to e-axle repairs, particularly for e-axles and the associated subsystems such as the electric motor, electric transmission, and electrical systems.

In 2022, Schaeffler Vehicle Lifetime Solutions presented the E-Axle RepSystem-G at Automechanika as a transmission repair kit for the battery-powered Volkswagen e-Golf. As the transmission and electric motor are contained in a single housing, the vehicle manufacturer only offers the entire e-axle as a spare part, without the option of a repair. With the E-Axle RepSystem-G, Schaeffler Vehicle Lifetime Solutions makes it possible.

Automechanika 2024 marks the launch of Schaeffler's second E-Axle RepSystem-G, a transmission repair solution for the Hyundai Ioniq. Like the Volkswagen e-Golf solution, the manufacturer only provides a complete replacement in the event of a failure but not a repair, as the repair kit with six bearings and seals include allows.

Additionally, Schaeffler Vehicle Lifetime Solutions will debut an E-Axle RepSystem-M at the trade fair for the Ioniq, enabling cost-effective replacement of the bearings in electric motors in the event of a defect. The kit contains two bearings, two flat seals, a rotary shaft seal, an O-ring, and sealing paste. In addition, the Schaeffler division, together with GEDORE Automotive, has developed a special tool to pre-production status, which enables contactless separation of the stator and rotor to avoid damage. Repair guides are already available for the two new solutions, and the relevant technical training courses are currently being prepared.

For hybrid vehicles: LuK disconnect clutch
Another product relevant to the aftermarket is available from the Schaeffler brand LuK: a complete repair kit for the “K0” automated disconnect clutch, which Schaeffler is also producing for series production. It can be found in many hybrid vehicles that feature a double clutch transmission and allows the electric motor and combustion motor to be used independently.

INA: Starting with three key technologies
Schaeffler Vehicle Lifetime Solutions also offers various thermal management solutions for combustion motors, hybrid vehicles, and fully electric vehicles under the Schaeffler brand INA, with two new thermal management modules being among the manufacturer’s latest additions to its range. These modules ensure demand-based regulation of the coolant temperature in various cooling circuits. The new repair kits, which will be presented at Automechanika in Frankfurt, enables the replacement of the thermal management module for various Mazda applications.

In addition, Schaeffler Vehicle Lifetime Solutions is expanding its portfolio to include electric auxiliary pumps for use in applications such as battery and inverter cooling. With the inclusion of combustion motors, the available versions cover more than 50 million vehicles – all in proven quality to OE standards. And finally, the manufacturer is adding new vehicle applications to its INA FEAD kits for 48V applications, which enable garages to professionally repair the auxiliary drive of a mild hybrid vehicle. In addition to a V-ribbed belt, tensioner pulleys, and idler pulleys, the kit also contains a belt starter generator (BSG) and all of the necessary accessory parts.

FAG: Experts in the overall chassis system
Intelligent chassis components also play a key role in electromobility, particularly friction-optimized NVH bearings, which reduce noise, vibrations, and harshness in the passenger compartment, while achieving a higher range. The Schaeffler TriFinity™ wheel bearing will feature among the products showcased by Schaeffler Vehicle Lifetime Solutions at Automechanika in Frankfurt and has been nominated for this year’s Innovation Award at the trade fair in the “Parts and Innovative Technologies” category. Specifically designed for use in electrified vehicles, the state-of-the-art, friction-reduced bearing offers increased performance, reduced friction, improved driving dynamics, low weight, and improved stiffness compared to conventional bearings, thereby contributing to the efficiency and performance of electric vehicles and supporting the development of sustainable mobility ecosystems.

Maik Evers, Head of Product Management Powertrain Systems at Schaeffler Vehicle Lifetime Solutions: “We at Schaeffler Vehicle Lifetime Solutions support the aftermarket in the holistic mobility transition. We are working to counteract increasing technical complexity by offering intelligent repair solutions that enable garages to service hybrids and electrically powered vehicles easily, efficiently, and profitably – an approach that is entirely in keeping with our motto for this trade fair: ‚Sustaining Motion. Pioneering Future’.”