“A new solution or product evolution is not a random event but the result of a structured and targeted process,” explains Florian Krebs, Senior Vice President, Advanced Innovation at ­Schaeffler. “Schaeffler’s innovations are based on many years of experience, exchange, and interacting ­processes. The analysis of customer needs plays an important role in that regard.” More than 70 percent of all successful product innovations are based on customer needs. They’re decisively affected by megatrends permeating all areas of life because of long-term, fundamental changes.

Schaeffler uses megatrends such as future mobility, automation, digitalization, or sustainability as a compass for its innovation strategy. “Mega­trends and the technology trends derived from them are not just buzzwords but important guidelines for our innovation strategy,” says Florian Krebs. “To address these trends and develop our ideas to success in the marketplace, we leverage our core competencies such as in-depth understanding of markets and customers, strong understanding of systems and products, manufacturing know-how based on our high level of vertical integration, and our materials and implementation capabilities.”

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“Of an initial 1,000 analyzed ideas only the most promising projects make it into one of our innovation programs.”

Innovation in clusters: Focus on targeted actions

To leverage innovation capacities in line with existing trends, Schaeffler focuses its activities on eight strategic areas called innovation clusters: Energy Solutions, E-Drive Solutions, Digital Solutions, Robotics Solutions, Software-Defined Solutions, Mobility Solutions, Material & Manufacturing Solutions, and Autonomous Production Solutions. “If an idea satisfies our assessment criteria and fits one of the clusters it migrates into our innovation-to-business process.”

“Of an initial 1,000 analyzed ideas only the most promising projects make it into one of our innovation programs. Important in that regard is the combination of the focus on market and customer needs and the required execution speed,” says Florian Krebs.

To ensure agile processes and bring innovations to market, Schaeffler is focused on three pillars. In addition to in-house innovation processes, the company deliberately uses external collaborative partnerships:

• Start-up Mode In that mode, employees focus on developing a specific subject until it has achieved a certain level of maturity. To ensure ideal conditions, those developments take place in a dedicated area but can continue to benefit from corporate advantages.

• Innovation Factory The team of the “Innovation Factory,” consisting of technical project managers, product development, and a prototyping section, is specialized in fast implementation, covering a wide variety of development expertise. They support the innovation clusters and assume responsibility for specific development projects. This is where innovative ideas are implemented in rapid prototyping stages. The objective is to realize breakthrough innovations in a global network.

• SHARE Concept The “Schaeffler Hub for Advanced Research” (SHARE) is a comprehensive cooperation model with leading universities worldwide enabling long-term and strategic collaboration in selected research fields along the innovation clusters. Direct access to the latest research and talent sustainably strengthens the company’s innovative prowess and accelerates the transfer of knowledge into tangible projects.

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Humanoid robotics: a prime example of Schaeffler’s innovative prowess

In the Robotics Solutions cluster, Schaeffler goes beyond the role of the user, positioning itself as a decisive systems supplier for the developers of humanoids. Humanoid robots need high-precision drive solutions, compact gearboxes, robust bearings, and smart sensors to execute human-like movements and to interact with their surroundings.

“Among other things, we develop specialty gearboxes and precision bearings that are not only extremely compact and lightweight but also offer the required stiffness and accuracy for the joints of humanoids,” explains Florian Krebs. These components are crucial for the robots’ constant agility, load-bearing capacity, and repeat accuracy. In addition, Schaeffler develops innovative actuator systems enabling precision control of humanoids.

The ideas for such highly specialized components often emerge from the requirements of the potential manufacturers in the field of humanoids and pilot use cases in in-house factories. Due to the close collaboration in Start-up Mode and in the Innovation Factory as well as the SHARE Concept, prototypes are developed and tested.

In-depth understanding of material sciences and manufacturing technologies enables Schaeffler to deliver tailored solutions going beyond the level of standard products and meeting the specific challenges of humanoid robotics. Consequently, ­Schaeffler not only helps enhance the efficiency of using humanoids in its own manufacturing operations but also supplies the crucial components enabling this technological revolution in the first place.

From a customer requirement to an innovation

Impetus, idea, innovation – Schaeffler’s innovation process promotes the development of sustainable technologies such as patented groove cooling for electric motors.

This forward-thinking development is a key element in Schaeffler’s striving to raise power density and efficiency to a new level. Groove cooling is an integral component of high-speed propulsion concepts reaching rotational speeds of up to 18,500 revolutions per minute.

Revolutionary thermal management for maximum power output
The capacities of electric motors are decisively determined by their thermal management. Conventional cooling systems reach their limits as demands keep increasing. Direct groove cooling developed by Schaeffler addresses that challenge in a unique way. Instead of relying on indirect or air-based cooling concepts, the cooling oil is used directly on the windings inside the grooves of the stator in this case. That approach enables direct absorption of the thermal energy losses exactly where they occur and their efficient dissipation to the thermal management system.

Efficiency enhancement and higher continuous output
A decisive advantage of this innovative cooling method is a significant reduction of acceleration- and friction-induced losses. Unlike cooling arrangements that may lead to a wet cooling gap, the air gap remains dry with this technology. That not only helps to enhance efficiency but also considerably increases the continuous output of the motor. Direct groove cooling makes it possible to adjust the motor’s continuous output to the maximum output level without incurring a risk of derating – which is a critical factor for performance and reliability in challenging driving situations.

Interaction of complementary key technologies
To complement this patented cooling technology, Schaeffler uses additional key technologies. A shaft winding in the stator, for instance, minimizes high-frequency losses while specifically developed high-speed bearings from Schaeffler reduce friction losses and ensure maximum durability and efficiency. The interaction between these technologies, embedded in a systematic high-speed concept for the entire axle, enables the high level of power density and efficiency that characterize Schaeffler’s electric drives.

With this patented direct groove cooling, Schaeffler underpins its position as an innovation leader in electric mobility.