Schaeffler heavy duty E-Motor. Foto: Schaeffler
There is no longer any doubt that electric drive systems will find their way onto construction sites in the future. The first local authorities in Germany and abroad are already banning the use of ‘combustion engines’ in sensitive urban areas. Schaeffler will be presenting new high-performance heavy-duty e-motors at bauma 2025 as a production-ready solution for purely electric and hybrid drive systems. Due to their design, they achieve particularly high torques, a power-to-weight ratio (peak) of around 5 to 7 kW/kg and maximum efficiencies of over 97% in a speed range of 3000 to 8000 rpm. The low losses of the liquid-cooled drive motors are essential in order to achieve long operating times between charging cycles on the construction site and to ensure optimum energy utilisation. Great importance was also attached to minimising losses and ensuring high operational reliability in the bearings and seals. Ceramic balls reduce bearing friction and prevent harmful current passage.
The modular motor series consists of three variants with maximum outputs of 125, 299 and 315 kW. They differ only in the length of the active part. The individual stator laminations and the A- and B-side end shields of the motors are identical in each case, enabling particularly economical production. With an overall length of 151, 206 and 261 mm and a standardised outer diameter of around 239 mm (laminated core diameter) or 280 mm (including screw connection), the motors require only minimal installation space. The stator windings are designed as flat-wire wave windings (Continuos hair-pin technology, also known as wave winding). At bauma in Munich, Schaeffler will be demonstrating a complete e-axis with an integrated heavy-duty e-motor.
Synergies: Automotive and construction machinery industry
The Offroad sector of Schaeffler’s Bearings & Industrial Solutions division has built up a comprehensive range of electric drives with a continuous output of 1 to 300 kW for the construction machinery industry through synergies from the automotive sector. Schaeffler has a large number of active components through to complete systems, such as wheel hub drives based on permanently energised synchronous machines. All key production technologies also come from a single source: the stator laminations stamped ‘in house’ as well as the coil windings manufactured automatically using hairpin and wave winding technology and the HV connector systems.
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