2023

Table of content Table of content

TABLE OF CONTENT

1 3
hofer powertrain & market development Product & service portfolio
Foreword of the CEO 4 Hybrid technologies 46

hofer powertrain – Locations overview 6 Advanced EDUs 48-55

hofer powertrain – Product portfolio overview 8 New technologies and innovations 56-71

Our values – Sustainable, efficient, economical 12 Cooperations, partnerships, programs 72-75

Market trends 14

Holistic EV evolution: Engineering, Innovations & Production 16

Project highlights and references 18-23

4
ULTEVATE platform 24-27

2
Global presence
Business areas updates & location news Presentations, events, speeches 76

SAE Engineering webinar: Traction motors innovations 77

Electronics & Software 24
Latest news on social media 78
Transmission & Testing 26

E-motor & Battery 28

Added location Vienna, Austria 34

Nuertingen & Wolfsburg, Germany 36-37

Estenfeld, Germany & Shanghai, China 38-39

Eschen, Liechtenstein 40

Budapest, Hungary 42

Warwick, UK 44

2 3
 Foreword of the CEO Foreword of the CEO

FOREWORD
OF THE CEO

Dear Readers,

I am excited to welcome you to the newest edition of our Our latest addition in Vienna, Austria, is set to increa-
Speed Magazine as we enter a new era in mobility. This se our speed in the development of electric drive units.
year has been a testament to our unwavering commit- This strategic location will allow us to serve our custo-
ment to innovation, collaboration, and sustainability, and mers in the area more efficiently.
I am excited to share our journey with you.
At hofer powertrain, we believe in the power of collabo-
Our focus remains steadfast on advancing powertrain ration. Our team, our partners, and our customers are
technologies for electrified vehicles. We have made si- the driving force behind our success. Together, we are
gnificant strides in the development of next-generation shaping the future of sustainable mobility.
power electronics, electric motor technologies and
battery solutions. All of our advancements funnel into In this edition of Speed Magazine, we delve into these to-
our comprehensive powertrain system the ULTEVATE pics and more, offering insights into our latest technolo-
platform. gies, company updates, and market trends. We hope that
you find this edition informative and inspiring.
Our battery business unit has been a cornerstone of our
growth, with a significant expansion of our battery deve- Thank you for joining us on this exciting journey.
lopment and testing facilities. We have been driving for- Here's to a future driven by innovation, efficiency, and
ward with technologies such as our Intelligent Battery sustainability.
Disconnect Unit (IBDU) and our Bluefire battery, capa-
ble of megawatt charging. We are also pioneering infra- Best regards,
structure solutions for megawatt charging, including our
patented Megawatt Charging Sections. Johann P. HOFER
CEO and Founder, hofer powertrain
We are proud of our successful projects, such as the de-
velopment of a two-speed transmission for a German
OEM sportscar and the creation of our ULTeBEAM solu-
tion, designed for the easy electrification of trucks.

4 5
1 Locations overview Locations overview
1

EUROPE
LOCATIONS
OVERVIEW

Global Presence,
USA
Technology Leadership: Germany
Troy, Mi
(Interface to the US market – decentralized development Your Partner in Nuertingen HQ
competence for the complete EV powertrain system) Development, Testing, (Strong EV battery expertise and infrastructure for testing and development)

Industrialization.

AMERICA
Wolfsburg
(Battery development and testing, transmission systems)

Stuttgart
United Kingdom (Expansive R&D + testing facilities for complete electric e-axles and transmissions)
Warwick
(Key interface to the UK market, specializing in electrified pow- Estenfeld by Wuerzburg
ertrain development and expanding battery testing capabilities ) (E-motors, power electronics, and software for the electric drivetrain, with state-of-
the-art testing technologies and high RPM facilities)
Solihull
(High-tech production facility, currently production hub for the Hepberg ( Vehicle safety and wiring harnesses, automotive safety)
8-speed high-performance DHT transmission)

Austria
Graz (Software & cybersecurity)
Liechtenstein

ASIA
Eschen St. Ulrich by Steyr
(System and electronics; (System: PE, VCU, software development
test, manufacturing and and cybersecurity.)
industrialization capacities)
Vienna (EDU and e-motor development)

Hungary
Italy Budapest
China Verona (Electronics and software: system
Beijing (Interface to the IT market – applications for control and cybersecurity)
(Hainachuan hofer powertrain: high-tech test and production transmissions and EV Powertrain)
center for eDRIVEs)

Shanghai (Interface to the Asian market -

local development team for eDRIVE systems and application)

Wuxi (High-tech test and production center for eDRIVEs)

6 7
1 Technology highlights Technology highlights
1

8 9
1 hofer powertr ain - Holistic partner hofer powertr ain - Holistic partner
1

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Customers worldwide

”In an era dominated by the increasing emphasis on e-mobility in the

automotive industry, it is essential to have a reliable, resourceful,
and innovative partner by one's side. hofer powertrain is exactly the
As an end-to-end engineering and technology of the future or expand further in a competitive and
kind of partner customers are looking for. hofer powertrain has been
partner of the automotive industry, hofer powertrain marketable manner. With decades of experience and driving innovation in powertrain technology for over 40 years and has
stands for innovation, strong expertise and high continuous proactive research & development, the established a reputation as an all-round engineering partner for its
reliability in the field of electric drives. With a deep experts have built up an extensive know-how in the field close customers and the automotive industry as a whole.
understanding of complete systems, future-proof of drive technology.
solutions and sophisticated technologies and advanced Wolfgang STEPHAN
implementation, the company ensures that customers CTO, hofer powertrain
successfully launch into the emission-free mobility

10 11
1 1

”
Our values Our values

hofer powertrain
It is our mission to
OUR VALUES
realize the most
efficient, sustainable
and economical drive
solutions.
Our corporate values have strengthened considerably
over the last few years and give us a clear orientation
as we move forward. These values are:

Sustainability Cost effectiveness

We focus on the development of environmentally friendly Our goal is to develop sustainable and economical solutions that are more
technologies that minimize the consumption of resources, cost-effective than current alternatives without compromizing performance
avoid the use of rare earths and are recycling-friendly. or functionality. We pay attention to the sourcing and development of each
component to ensure a robust and proven supply chain.

Efficiency Electrification
To exploit the full potential of each individual component and ensure We are convinced that the future of mobility will be defined by electrified
minimal energy loss, a profound understanding of the entire system drive systems and their efficiency. This motivation is reflected in our
is required. We strive to develop powertrains that offer the highest efficiency. values and has been anchored since 1991, when our team realized
the first electrified drive.

S. 24 S. 58 S. 60 S. 64 S. 54
A selection of technologies: PLATFORM
Form Litz Wire GaN Electronics ULTeBEAM

12 13
1 Market de velopment and trends Market de velopment and trends
1
Passenger cars Motorsport and high-
MARKET DEVELOPMENT The number of new registrations shows a positive de- performance vehicles
velopment in the electric car market not only in Germa-

AND TRENDS
ny, but also the worldwide sales in 2022 and more so in Similarly, the hypercar market is shifting towards elec-
2023 have increased enormously. trification, with electric hypercars expected to double
their market share by 2027. Around 60% of hypercars
sold worldwide will be electrified by 2025, as demand
for more sustainable, high-performance vehicles inten-
Off-road recreational sifies. The growing popularity of the Formula E is also

vehicles driving electric motorsport, requiring both more innova-

tive designs and better fast-charging technologies.

Driven by the growing popularity of off-road recreational

and leisure activities and stringent emission regulations,
the market for electric off-road vehicles promises to Here hofer powertrain offers
grow rapidly too, with demand for electric vehicles such targeted solutions with the
EVs are gaining in popularity and studies show their lo- In 2023, we are already seeing an increase in the use as quads, off-road motorbikes and ATVs on the rise. HCTV+EDU ( 720 kW), which
wer carbon footprint compared to internal combustion of electric vehicles, but the real leap in electrification makes 1440 kW possible in twin
vehicles in Germany. Emissions are 40% lower over the will only be apparent in the near future, and hofer design (rear & front axle)!
car's life cycle and the environmental benefit continu- powertrain's development expertise is set to be signifi-
es to grow due to increasing use of renewable energy. cantly more in demand between now and 2030.
Policymakers continue to promote electrification. Cur-
rently, China and the USA are leading the BEV indus-
try. However, the European Automobile Manufacturers
Trucks
Association (ACEA) also forecasts a revival of the Eu- The market for electric
ropean battery electric vehicle (BEV) market by 2025. trucks is expanding
As a result, Europe is expected to overtake both China In 2022 and 2023 the number of heavy trucks rose. De-
and the US in electrification leadership by 2030. Other spite making only 9% of the global vehicle stock, they
markets are also gaining momentum. cause 39% of greenhouse gases (5% of global CO2 emis-
sions). Half of the EU's transport volume (under 300 km)
could already be carried out up to 90% electrically.
And the range of electric trucks will continue to grow.
(See our latest developments and competencies for this
area: page 42).

In Germany, focusing on metropolitan areas and smart

and intelligent infrastructure are key strategies for
low-carbon freight transport. (Read our latest article
Quelle: ACEA, S&P Global Mobility;
Note: including passenger cars, pickups/light trucks but excluding vans on the new patent for a multi-sector megawatt overhead
charging concept at www.pressebox.de).

14 15
1 holistic EV e volution holistic EV e volution
1

HOLISTIC EV EVOLUTION:
ENGINEERING, TECHNOLOGY (IPs), INDUSTRIALIZATION
1

Growing innovative power paired with strong

Driven by the need to accelerate e-mobility and offer Today, more than 60 patents can be counted. Finally, the engineering expertise
the best products to the industry, hofer powertrain industrialization knowledge and manufacturing capabi-
achieves its goals by leveraging three core business lities come from highly experienced delivery teams, the
pillars: Engineering Services, Technologies and IPs, and strong supplier, and partner network, and the modern The engineers and technical staff have a wide range of interdisciplinary skills, which they use to meet the
Industrialization & Manufacturing. production facilities. individual needs of the customers in the best possible way, thinking outside the box.

The first pillar, Engineering Services, comprizes a wide

”
range of offerings that enable Tier 1 and OEM customers
2
around the world to access engineering knowledge, ex-
pertise and tools from many engineering disciplines.
Using in-depth market knowledge Emerging future-proof technologies
With over 750 major projects on the books, the teams
and by proactively developing future-
have a deep understanding of the entire electric drive
proof technologies, we stay ahead of hofer powertrain places great importance on developing future-proof technologies that meet the increasing
system.
the market to deliver the best for our demands of electric mobility. These include, for example, highly efficient electric drive axles, powerful bat-
The second pillar, Innovation & Licensing, involves the customers, whether they need hofer tery systems and intelligent control units. With such technologies, the company is helping to accelerate the
development of groundbreaking e-mobility products powertrain as an engineering expert, switch to zero-emission mobility and drive the transformation in the automotive space.
and technologies, such as the ULTEVATE 2.0 platform solution provider, or technology
and 800 V booster technology. hofer powertrain's moti- partner.
vation to innovate is demonstrated by the number of its
patents and in-house developed innovations that have Wolfgang STEPHAN
3
quickly captured the attention of the market. CTO, hofer powertrain
Sophisticated, rapid implementation

Our experts focus on careful planning and execution of all projects, using state-of-the-art and new tools
Engineering Services Production capabilities and processes to ensure that the solutions developed are not only technically flawless, but can actually
We provide our customers Through our developments and
be realized in an cost-effective and efficient manner. By focusing on sophisticated implementation,
with full-scope support from manufacturing experience world- hofer powertrain guarantees its customers the highest quality and high level of satisfaction.
conception and planning through wide, a highly qualified network of
the development and integration of contacts in all areas and regions is
all essential components into the accessible to our customers.
complete powertrain system.

Innovations &
Strong projects & recurring customers
Licensing
Offering a wide range of With an impressive track record of first-class customer reference projects, the hofer powertrain team
specialized products to meet has established itself as a reliable partner in powertrain development. The increasing number of recurring
the individual requirements of and new customer projects is evidence of the quality of the work that hofer powertrain delivers in the
our customers. automotive segment.

16 17
1 Engineering excelence Engineering excelence
1

2-Gear EV transmission development for German

OEM sportscar

END TO END hofer powertrain has the proven ability to accelerate the mobility evolution of
premium sportscars through proprietary technologies and leading engineering
know-how in creating efficient mobility solutions

ENGINEERING EXCELENCE Services & products:

• Conceptual desin • Alternative concept
• Development, procurement of development after series
parts, and production production
• Continuous support in the
development (B-sample phase)

High-performance hybrid transmission development for

Engineering services are an essential part of our mission to bring efficient powertrain solutions
a one of a kind hypercar application with e-reverse
to today's mobility consumers. We strive to help them move their engineering projects from
concept to production in record time.
The customer inquired about a transmission solution that achieves the highest

Engineering Highlights 2022-2023

efficiency in the size-performance ratio. We started in the concept phase and
delivered a ready-to-run series solution for the McLaren Artura supercar.

Services & products Tools

• Components selection & design • CAD
hofer powertrain provides new inverter technology for a optimized for a high-speed application • Simulation software / CAE
globally renowned powersport customer • Gear layout calculation • Test rigs (component and
• Lubrication system design system tests)
Market leader in off-highway and recreational vehicles required a new inverter • Testing & validation (special high-
solution. In developing and realizing new concepts, it was possible to successfully speed tests)
meet the highest market requirements for the functional safety of the entire • Series production
system, including the electronics and mechanical systems, thanks to the strong
interdisciplinary engineering and testing expertise of various locations and
teams.

Services & products Tools Development of an AMT transmission control software

• Inverter concept and design A and • CAD for a hybrid hypercar powered by formula-1 technology
B samples • ANSYS
• Pre-validation B sample • CAE
• eDrive system design support • Matlab Simulink The engineering team developed and integrated transmission control software
• IP transfer hardware + software and an HCU of an extra class to achieve fast shifting and an uncompromising
driving experience that complements the transmission's extremely high
speeds and performance. With the focus on the highest functional safety, this
system was developed, calibrated, and tested using a model-based approach,
according to the ISO26262 standard. All safety-critical (ASIL D) functions of
all transmission sub-components and the entire system were validated and
verified in numerous in-house tests and customer vehicles, leading to the series-
production readiness.
Development of advanced analysis methods for a Services & products Tools
new high-voltage battery for a renowned EV manufacturer
• Full-scope development • Matlab Simulink
• Testing • Vector CanApe
Upon request of the customer, new measurement and analysis methods were • Calibration • TargetLinnk
developed to provide detailed assessments of new-generation batteries, their • Doors
current state, and their degradation behavior. These simulation methods and
testing equipment enabled accurate forecasting, testing, and optimization of
battery performance. Additionally, the new insights led to significant optimization

Discover all
opportunities for thermal management on module and battery pack levels.

Services & products

• Improved measurement analysis • Development of new engineering services
of the cell module testing methods
• High-precision simulation • Building of test rigs for www.hoferpowertrain.com/engineering
methods high-precision, large-scale
18 testing 19
1 Reference customer projects Reference customer projects
1

PROJECT HIGHLIGHTS – ZOOM IN

8 -SPEED HYBRID TRANSMISSION

DEVELOPMENT OF 2 UNIQUE WITH E-REVERSE GEAR

ELECTRIC DRIVES Solution

FOR A RENOWNED ENGLISH The development of the unique hybrid drive with an electric reverse gear began with the goal of gaining
a strong competitive advantage in the highly competitive hypercar sector. To exceed the expectations of
sports car enthusiasts, an innovative concept was developed: an 8-speed transmission with an electric rever-
SPORTS CAR AND HYPERCAR MANUFACTURER se gear. This forward-looking design was intended to be not only powerful, but also extremely compact and
lightweight, to be in line with the requirements and specifications of the visionary OEM.

Two electric drives were developed for one of

England's best-known high-performance and racing
Testing & simulation Challenge
car brands.
The greatest challenge in the development phase was to find a balance between a state-of-the-art design,
Review and simulation of different concept extreme compactness, unprecedented performance, and maximum efficiency. For this, an external electric
During the concept and design phase, various concept variants at component and system level machine was integrated into the hofer powertrain transmission system, taking into account the interfaces
variants were investigated and comprehensively simula-
to the customer system from the very beginning. The exceptional design was achieved through numerous
ted at component and system level, including hydraulics,
simulation cycles and the constant optimization of simulation models and tools.
parking lock, and transmission.

Additional components
Conceptual design Design
Inclusion of hydraulics, parking lock, and trans-
The validation of the simulations, calculations, and the final system was carried out through continuous
Development and design support mission in the development process
high-load testing throughout the entire development phase. This enabled errors to be detected and elimi-
nated early on before the project moved on to the next stage of development. To ensure high quality, our
engineers explored the performance limits of the developed transmission on several test stands.

Industrialization

The industrialization of this solution has been successfully secured by the joint venture in Solihull, where
production has been in full swing since 2021. The quick setup of the entire production plant, expertise in
industrialization and process development, distinguish this project. The plant focuses on the production
of this transmission, with several thousands of units already leaving our factory in 2022 and more in 2023,
offering maximum flexibility to also realize other customer projects at this location.

20 21
1 Reference customer projects Reference customer projects
1

REVOLUTIONIZING COMPLETE ELECTRIFICATION

OFF-ROAD MOTORCYCLES OF A MUNICIPAL EQUIPMENT CARRIER

A NEW HIGH-SPEED E-MACHINE FOR A RENOWNED CUSTOMER

DEVELOPED FOR MAXIMUM EFFICIENCY

Outcome

The vehicle operates on a 400 V DC system, offering both AC and DC charging capabilities, with a robust
battery capacity exceeding 50 kWh. It is further enhanced by a suite of innovative features such as advan-
ced thermal management, water-cooled components, an efficient heat pump, and a unique torque vectoring
control.

Development of a highly integrated and compact EDU From concept to a complete vehicle demonstrator
with reduced weight and smallest package
In 2023, a demonstrator of the vehicle was showcased to the industry, demonstrating the versatility of the
electrification solution, which is suitable for various types of vehicles including utility, municipal, and specia-
hofer powertrain is accompanying a renowned client, a lized machines such as fire trucks and construction vehicles. Throughout this project, hofer powertrain over-
manufacturer and global leader in off-road vehicle pro- Max. reduced packaging saw specific component specification, system architecture development, component integration, whole
duction known for its excellence in off-road motorcy- vehicle configuration, and software development, ensuring consideration of all electrical and mechanical
cles and sports cars, with a long-standing history. The
and weight
interfaces for a seamlessly integrated and efficient electrification solution.
new development in the area of 50 / 60 Kw peak 30 Kw
continuous output is a highly integrated and compact
EDU. The focus in the development was on reducing
the packaging, use of a high-speed e-machine, which
Integration of all
was installed in a highly compact manner. One of the
challenges was the integration of all components and components
maximally reduced packaging and weight, without mo- All components Vehicle setup
ving the output of the gearbox. Since the performance specification / integration
of high-speed e-machines drops significantly, several
concepts were developed that maintain high efficiency Development of several
at even the highest speeds. In this process, a low-loss
concept was created with significantly better properties
concepts for efficient
compared to existing solutions. This is used not only in high-speed motors System architecture Software development
80 PS motorcycles, but can also be used in city scooters
or similar applications.

22 23
1 ULTEVATE pl atform ULTEVATE pl atform
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ULTEVATE
DISCOVER OUR ALL-IN-ONE SOLUTION

Highlights
THE MODULAR EV POWERTRAIN SYSTEM

1 4
100 mph - 200 mph maximum speed In accordance with international
automotive standards (functional safety
and cybersecurity)
2
Complete system integration possible 5
The ULTEVATE system comprizes a High performance and NextGen drive within a modu- through hofer powertrain Single and dual EDU architectures
variety of turnkey solutions along lar EV platform that combines the highest efficiency
with a future-proof technology and sustainability with the most economical design,
while allowing for multiple power classes and custom 3 6
roadmap.
applications. 400 V & 800 V solutions available Calibration according to the desired driving
characteristics of the vehicle

Electric Drive Units Battery solutions

ULTEVATE EDUs offer customers the freedom Based on the ULTEVATE battery platform, hofer
to choose from a wide range of applications and powertrain offers tailored solutions including
performance categories. battery management and charging systems.

Electronic controls Software &

Functions Multiple options for platform
All necessary control units and power electro- Software and functions for the entire pow- configurations
nics are included in the design of the platform. ertrain tie everything together and add another
These are available with different semiconduc- layer of customization possibilities, including Depending on performance and functional requirements, customers get the
tor types and comply with the highest safety application and calibration of the software. opportunity to create their own system configuration – from ready-made to
level ASIL D. customized solutions including system integration by hofer powertrain.

Learn more about the platform on the next page!

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1 ULTEVATE pl atform ULTEVATE pl atform
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PLATFORM
2.0
MORE FLEXIBILITY IN THE DESIGN OF eDRIVES

Highest adaptability and

Our ULTEVATE platform continues to evolve with the needs of our
customers and the market. The original portfolio has been expanded to scalability
incorporate solutions based on multi-disciplinary synergies to meet all
industry needs and provide superior solutions for future resilience. Distinctive levels of performance and efficiency are possible with different system set-ups on the axle, giving
more freedom to design and innovate at different drive levels. By opening up new possibilities for new archi-
tectures, the portfolio gives a significant boost in any engineering project in the worldwide
automotive sector.

Engineering in tune with New additions to our

the environment ULTEVATE portfolio
Our efforts are aimed at reducing the use of materials, metals, and rare earths in systems. The focus of our The wide-ranging system expertise in powertrain solutions and other systems, coupled with the lean organi-
battery teams is on investigating the swelling behavior of cells, cell chemistry and ageing mechanisms to optimi- zational structure of hofer powertrain, puts us in a unique position. It enables our teams to enter into a cus-
ze battery solutions, with an additional focus on research and development of propagation-free systems at the tomer project promptly at any time and to implement new solutions according to the most unique, individual
module and battery pack level. requirements.

Ultimate overall efficiency Cutting-edge technology

and performance boost and continuous progress
Various ULTEVATE configuration options open up new chances for more future viability and versatility with As a technology company, we are continuously developing our platform and shaping our technology pipel-
different performance levels and customization options. Cost-effectiveness is our top priority in every engi- ine to meet future needs, including technologies for 800 V+, new semiconductor systems (GaN), ultra-fast
neering project. With this platform approach, even the most ambitious technical goals can be achieved. charging capabilities, processes and technology, and new winding technologies such as Form Litz Wire
winding technology.

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1 ULTEVATE pl atform ULTEVATE pl atform
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Electronics Software
In the past year, our department Electronics has made significant progress, The business area Software is developing rapidly, with the overarching goal
reflecting growth in organizational capabilities, technical knowledge, and of creating an even more robust structure that complies with strict automo-
industry innovation, primarily through hands-on customer projects. tive standards such as ASPICE, FuSa, and Cyber Security.

This ensures the delivery of high-quality results for customer requirements,

The large team distributed across multiple locations focuses on topics related supports projects, and fosters growth through collaboration and knowledge
to the inverter and hones its expertise in hardware architecture, functional sa- transfer across different locations. Through our extensive experience with ma-
fety, control devices, and more. jor automotive players, we bring maximum advantage into all new projects.

The large team is continuously working on optimizing We've begun transitioning to the TC3 microcontroller,
The new structure of the department demonstrates ad- 800 V Booster 3L Inverter processes, with a particular focus on secure data pro- meeting current automotive market demands, in colla-
vantages, leading to improved workflow and efficiency cessing, expanding simulation expertise, improving bidi- boration with other business units. Looking forward to
in handling an increasing number of projects. By focu- rectional traceability, and increasing security for cyber- the DC4 update, it provides superior memory, connec-
sing on better assessment techniques, simulation me- security-critical software. tivity, performance, and advanced safety for next-gen
thods, and thermal analysis, we have refined our work eMobility.
structures in various areas. The commitment to high standards was evident during
GaN Chip Technology
an external ASPICE assessment in a project for a re-
Achievements and exciting
nowned hypercar manufacturer. All assessed processes
software projects
At the forefront of our innovations is the achieved ASPICE Level 1. Subsequent development led
development of a three-level (3L) inverter that to audits regarding process compliance and functional
addresses the industry's need to reduce harmo- safety, with the final assessment in June 2022 demons- Current projects encompass not only develop-
nic losses and overall vehicle consumption using trating compliance with the functional safety standard ment projects but also software industrialization
gallium nitride (GaN) devices, with the aim of in- for high-performance models, receiving ASIL level B and projects, ranging from requirement generation
troducing less costly, high-performance systems D. to state-of-the-art inverter software solutions
for the automotive world in the near future. The that are production-ready. The efficiency
compatibility of the existing 3L topology with evaluation of the 3L inverter control software
Significant steps in cybersecurity
GaN technology has been tested, yielding pro- compared to 2L inverters has yielded impres-
The hofer powertrain ONEboard
mising results. Further development and testing sive results, with tests being conducted within
for higher-power applications are underway, hofer powertrain has also taken significant customer projects. The sustained demand for
Our ONEboard maintains a strong presence with positive feedback from the industry and steps in the direction of cybersecurity and has transmission platform software continues to
in the global market and has undergone con- ongoing discussions with major customers. assembled a highly qualified team to meet the bring in projects, especially for dedicated hybrid
tinuous refinements to ensure its ongoing constantly growing requirements of the future. transmissions (DHT).
success. (Page 36)

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1 ULTEVATE pl atform ULTEVATE pl atform
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E-Motor Battery
The newly defined business unit Batteries and Mechatronics commenced its
In the past year, the electric machine department at hofer powertrain has operations in 2023.
further expanded its capabilities in both electromagnetic and mechanical
design. As early as the end of 2022, the key steps were initiated to merge the previous-
ly separate development areas of Hydraulics / Mechatronics and Battery with
As always, our goal is to develop groundbreaking, profitable, and sustainable the Battery and Hydraulic Testing department, which had already experienced
technologies. In doing so, we focus on new development technologies such as further growth and development before the official merger last year. The de-
the Form Litz Winding technology in stators. (Read more about this on page 60). vision is growing at a very fast pace, expanding into different other locations
including outside of Europe.

By closely observing market trends, our experts can chine development include the transition from 400V Our hydraulic system testing offering has been expan- ponents, especially for specialized applications with
align our products and engineering services with spe- to 800V in certain countries, while others have already ded with new custom-built test benches for specific hydrogen and gas. Our long-standing expertise in Cam
cific requirements such as fast charging, efficiency im- shifted their full attention to increasing voltage to 800V customer requirements. The in-house environmental Phaser design helps us deliver new design families for
provement, and material savings. Trends in electric ma- and even higher. tests prove to be a valuable resource with high custo- global customers who are developing engines and see-
mer demand. Performance tests and safety validation king support in this area.
Axial flux motors tests are efficiently conducted in our new test field in
Future-oriented winding technologies Wolfsburg, thus complementing our expansion strate- We've initiated a comprehensive program in our busi-
gies. In 2023, the team is intensifying its focus on additi- ness unit for ongoing refinement of internal processes,
We are increasingly focusing on axial flux onal core elements of battery module and pack testing, tools, and methods, targeting all battery related areas.
Due to recent supply chain events, the industry machine technologies due to their suitability for including battery cycling, standard tests, and certifica- This strategy aims to sustainably boost operational ef-
is turning to the externally excited synchronous limited space and high torque requirements. As tion processes. Lifecycle tests are becoming increasingly ficiency and quality outcomes across all battery projects.
motor (EESM) and its potential as one of the the market for axial flux motors is expected to important, and the team is expanding its already strong
forward-looking solutions. Our ongoing explora- reach $355 billion by the end of 2026, we stra- competencies and capacities. Of particular note is the
tion of more efficient winding technologies aims tegically continue to pursue this direction and further development in the field of vehicle safety, with
to optimize industrialization and increase the provide customers with development support in a consistent commitment to expanding the crash test
overall efficiency of electric motors. their projects. environment. Here, the existing mechanical expertise
complements the area of battery testing in crash tests,
revealing synergies and allowing batteries to be compre-
iBDU
hensively analyzed, opened, and scrutinized.
High-speed e-machines
Our initiative to optimize internal tools and methods is With increasing demand, our team and resources for the An exciting innovation is the iBDU, an intelligent
crucial here, enabling us to adapt to the latest techno- cell testing area are expanding, supported by new cell Battery Disconnect Unit, which provides OEMs
Among other things, the development of logical advancements. We have made significant pro- testers who can test cells simultaneously on multiple and battery suppliers with intelligent, centralized
high-speed electric machines for specific gress in improving our thermal models, expanding our channels. In the coming year, we aim to strengthen our battery control and uncompromising safety,
requirements, with the aim of achieving high cooling test benches, developing innovative electroma- relationships with existing customers, acquire new cus- promising cost savings. There is already great
performance with minimal volume and weight, gnetic solutions, and optimizing our internal simulation tomers, and expand test fields at new locations. interest from some of the major customers, and
is a focus. At the same time, we are testing toolchain. By keeping pace with evolving trends and in the future, this technology can be offered in
new cooling methods and systems to further requirements in the electric machine field, hofer pow- Despite the rapid pace of electrification, we recognize the form of license and IP options.
optimize power density and thereby improve ertrain reaffirms its commitment to shaping the future the ongoing need for internal combustion engine com-
overall efficiency, performance, and cost factors of e-mobility.
for OEMs.

30 29 31
1 BU-Updates BU-Updates
1

Transmission
The business division Transmission has made numerous advancements over
the past year.

The team continues to deliver projects from the concept phase to full series
Testing
production, serving a wide range of automotive customers. An increasing num-
ber of projects involve multiple business units, reflecting our integrated, holistic The division Testing operates at high capacity, achieving an utilization rate
system approach. of over 90% at multiple test benches. This indicates a robust and active
testing environment as well as high project utilization.

The remaining time is carefully used for maintenance and downtime to ensure
Through strategic organizational changes, we have at the forefront. The rise in customer projects shows a the delivery of the highest quality of these test benches and reliable results
transferred several experts from the Systems business strong demand for multi-speed and high-speed systems, with the methods used.
unit, known for their NVH (Noise, Vibration, Harshness) and novel solutions. Besides familiar platforms like KISS-
expertise, to a new, specialized team within the Trans- soft, we also employ simulation platforms such as MAS-
mission unit. This has expanded our capabilities and TA, broadening our toolkit.
enables us to perform a wide range of simulation work,
from traditional customer-requested investigations to
complex crash simulation procedures at the housing and Mechatronics and Battery Testing business unit remains
component level. The growing demand for our services has led to certain unchanged, with synergies being utilized that benefit
Designs, test benches reaching their capacity limits, necessitating both units and some of their customers simultaneously.
The thermal management team, together with other including L and a reorganization of some tests. To facilitate this, we have
areas responsible for the development of Electric Drive XL versions begun expanding our testing capacities at our Austrian Our team is developing a deeper understanding
Units (EDU), has experienced significant improvements sites, where new test benches with additional engine of the assessment and improvement of noise
– despite increasing power density, our deepened un- power have been installed. Here, our 8-speed DCTs un- and vibration behavior (NVH). In addition, we
derstanding has contributed to innovative solutions, The High-Compact Torque Vectoring (HCTV) derwent extensive testing, and the testing field now also are working on new testing methods and setting
such as a fully enclosed EDU, with a completely new project particularly stands out in 2022-23. offers local customers easier access to the entire testing up tests to balance rotating masses. Moreover,
cooling system for dissipating residual heat. know-how. As part of a recent strategic realignment, the we have implemented our own early damage de-
A particularly compact high-performance drive business unit is increasingly focusing on component and tection systems, which are particularly important
Advanced techniques for analyzing interfaces enhan- system, which offers many advantages in L- drivetrain testing, transferring other focus areas to the for durability tests for customers. This initiative
ce parameter accuracy. Refining these models not only architecture, has led to an increase in customer respective units (e.g., battery tests) to ensure the high- reduces our dependence on external suppliers,
boosts their quality but also prepares them for system inquiries for diverse solutions based on our est degree of specialization. Patrick VIKARI took over thus making hofer powertrain more self-reliant
use. Our new Tools and Methods program continuous- HCTV. The versatility of the system allows for the management of the business unit at the beginning and improving the ability to provide exceptional
ly upgrades our toolchain, promising distinct outcomes various configurations, including the L and XL of 2023 and brings a dynamic vision for efficient and service.
for clients. Modern transmission solutions are becoming versions. ambitious testing processes. The collaboration with the
increasingly complex. In gearbox development, we are

32 33
2 Added Location: Vienna Added Location: Vienna
2

ADDED LOCATION: VIENNA

All core competencies of the
hofer powertrain group are
also transferred to the new
location. Stronger focus will
be placed on the following
areas:
1
Expertise in inverter development: complete
development and optimization of power
electronics for electric drives

2
Integration of drive components and
systems for optimal performance and
efficiency

In the past five years, Vienna has made a name for itself The new location not only offers optimal infrastructure
3
as an engineering hotspot for e-mobility. With the ope- and connections, but also numerous opportunities
Development and production of high-
ning of the new hofer powertrain site in the Austrian for collaboration and networking with educational performance electric motors for various
capital, this growing importance and demand in the in- institutions and international events. Through its applications
dustry is recognized. On April 17, 2023, the site was put presence at the key e-mobility and automotive
into operation under the leadership of Klaus WAWRA. engineering conferences, hofer powertrain further
4
Even before the official opening, the company was able strengthens its position in the industry.
Implementation of customer-specific
to win its first qualified automotive customers who trust solutions for powertrain systems
the engineering expertise of hofer powertrain.

”
Implementation of individual customer
requirements in powerful and unique
eDrive technologies
Our priority in the first months after the opening was
to quickly provide resilient concepts and first-class
6
engineering competencies for our customers. This has Development of technologies for growing
been reached with our currently growing team. market requirements, taking into account
market trends such as 800 V and higher
voltages, faster charging, higher power
density, improved efficiency and reduced
Klaus WAWRA production costs
Location manager Vienna, hofer powertrain

7
Simulation work, analysis, and optimization
of all powertrain systems and subsystems
up to the vehicle level

We are hiring!

Join us to turn visions into efficient and

future-proof drivetrain technologies!
34 hoferpowertrain.com/jobs 35
 2 Location Updates Location Updates
2

NUERTINGEN GERMANY WOLFSBURG GERMANY

Leadership through advanced battery development and Transmission development and further strengthening of the
test practices with a technology-open approach battery-related capabilities with advanced battery testing

From 2021 until today, our leading battery development and

test center in Nuertingen has experienced an unprecedented
and rapidly growing number of inquiries. We recorded more
orders from customers than at any time in the past. To meet
Additionally, new patents and innovations have emerged in
2022 and 2023, such as the iBDU, an Intelligent Battery Dis-
connect Unit (Page 64). This unit, now in its second genera-
tion, delivers outstanding BOM cost benefits among others.
”While transmission development stays a big point of focus, the surge in market demand
over the past couple of years has impelled us to persistently broaden our in-house battery
development and testing capabilities, supporting our battery competence center in
this growing volume of highly complex customer projects, we This solution has already generated an overwhelming market Nuertingen, thereby strengthening the services we offer our customer base.
have devoted more attention to high-demand and forward- response from major OEMs and Tier 1 suppliers, even before
looking development topics, bringing some innovations to its official launch into the market.
the market along the way. Examples of our in-house deve- With the growing demand for battery development services
Martin AMTHOR,
lopments include our scalable ULTEVATE battery (Page 30) and solutions, more and more customers are relying on our
and the brand-new BlueFire fast-charging battery (Page 66), functional, end-of-line, durability, endurance, and environ- Managing Director
which was first introduced at the Battery Show 2021 and has mental tests. This diverse and rapidly expanding range of ser-
attracted numerous renowned customers since and has led to vices in all battery test areas ensures that all customer needs
several new concepts and developments including our Flash- are met and allows for customized adaptation to various test This strategic move has proved to be a significant stride for- of vehicle safety by enhancing our crash test environ-
Charge for LMDe vehicles (Page 68). environments. ward. Now, we're channeling our efforts to enrich key areas of ment. The existing mechanical expertise we possess
battery module and pack testing, from battery cycling to stan- creates a harmonious fusion with battery testing in
dard tests and certification processes. The increased impor- crash scenarios, unveiling synergies that facilitate

”
tance of lifecycle tests has prompted us to bolster our existing comprehensive analysis, deconstruction, and scrutiny
skills and resources. We're notably making strides in the realm of batteries.
In light of the increasing electrification of vehicles, the global demand for certified and
validated traction battery solutions that are safe for people continues to skyrocket. To
optimally support our customers in this process, we use our in-depth battery understanding
and pioneering test solutions and we are equipping additional locations with the necessary
We are hiring!
expertise and testing facilities to conduct numerous high-volume battery tests.
Join us to turn visions into efficient and
future-proof drivetrain technologies!
Lars ILLGEN,
Senior Manager, EV Battery Testing hoferpowertrain.com/jobs

SHARED BATTERY EXPERTISE IN NUERTINGEN AND WOLFSBURG AS WELL

AS EXPANDING TO SEVERAL OTHER LOCATIONS SOON

Single point of contact for all Safety, environmental, and abuse Consideration of both national Independent coordination of all
energy storage needs tests and international safety standards test activities
Comprehensive development and testing of Significant trends in battery development Safety compliance is ensured under unified Preparation, execution, and post-processing of
battery systems by hofer powertrain covering include high voltages and increased perfor- standards various test results, including documentation,
cells, modules, and battery packs mance ranges. Safety is the be-all and end-all logistics, storage, and recycling
factor here. We study the behavior of batteries
within the most diverse cases and bring clarity

36 37
 2 Location Updates Location Updates
2

ESTENFELD GERMANY
hofer powertrain
Competence Center for Electrified Powertrains

IMPORTANT PART OF THE HOFER POWERTRAIN

GROUP SYSTEM CAPABILITIES

x ”hofer powertrain site in Estenfeld symbolises more than just a physical location. It is a vital
hub for strong engineering competence, advancements and successful customer projects.
Over the course of 2023, this location´s capabilities and capacities will be majorly expanded
Power electronics for a wide
range of vehicle applications
Many years of hardware design and devel-
opment experience incl. mechanical design,
and implementation according to the latest
E-machine design & engineering

We offer services from electromagnetic design

and mechanical construction to developing
innovative cooling, connectivity, and interface
to meet the increasing demand for electric propulsion development and to reinforce its automotive standards strategies.
position in the development of powertrain technologies.

Wolfgang STEPHAN Testing and optimization of

Reliable and safe control software
CTO, hofer powertrain drive technologies
Software development for power electronics Rapid prototyping, component tests, and reli-
(BSW, ASW), effectively controlling all critical able, detailed system tests of electrical drive
systems of today's complex car models systems

Focusing on testing and industrialization competencies today and more so in the future. By bridging skills and
and development resources in areas such as control resources across our locations, Estenfeld is pivotal in
software and electronics, this center is not just a delivering unparalleled services to the broader industry
standalone unit but operates in tight-knit collaboration
with our various global outposts. The unique know-
and meeting the exacting standards our customers
expect. This integrated approach underscores our
We are hiring!
how and experience of the teams can be found in commitment to quality, setting us apart as a leading
solutions of all kinds in various vehicles on the road industry partner. Join us to turn visions into efficient and future-
proof drivetrain technologies!

hoferpowertrain.com/jobs
38 39
 2 Location Updates Location Updates
2

BEIJING CHINA SHANGHAI CHINA

”
With successful projects varying from conventional automatic transmissions to pure
EV projects, more and more vehicles in this market are "powered by hofer powertrain
engineering." It makes us proud to see great reviews from traditional customers like JAC,
SAIC, FAW, DFM, and successful start-ups like NIO shared with the industry via "good
products." Following the lead of our colleagues worldwide, hofer powertrain Shanghai
now also steps into the off-highway and heavy-duty vehicle and powertrain field, serving a
broader market soon.

Chen Zhaoxi
Head of Powertrain Development Center, China

”
Over the last ten years, the domestic automobile market in China Our development center in Shanghai builds a technological
has become one of the largest vehicle markets in the world. and consulting bridge, bringing important hofer powertrain
As the Deputy General Manager of Engineering, I am thrilled to be a part of our JV in The market demand for cutting-edge technology is increasing. engineering services and competence to our Chinese customers.
Beijing, championing the creation of pioneering electric drive units. With our unwavering Very short development periods, constant design requirement The Shanghai team's strength is an accurate understanding of
changes, and fast response are only a few of the many challenges customers' wishes and the desire to bring new technological
commitment to quality and cost-effectiveness, we're not just manufacturing powertrains –
of this industry. innovations closer to the market.
we're driving the future of electric mobility in China and beyond.

x
Lawrence HOFER
Deputy General Manager, Hainachuan hofer powertrain
E-POWERTRAIN DEVELOPMENT, TESTING, AND
CONSULTANCY FOR THE CHINESE MARKET
RAPID DELIVERY OF ADVANCED ELECTRIC AXLES
TO THE GLOBAL MARKET
eDrive engineering and testing Proximity to our local customers

We engage in the development of all single

Technology & Engineering Industrialization & Production components and entire powertrains for Direct availability for all Chinese customers
EVs across all power ranges, up to 800 V with no time zone difference and no language
With our strong technology roadmap we are Excellent facilities, combined with our strong applications. Our development expertise is barrier allows us to help our clients with our
setting the course for a significant step towar- and proven industrialization capabilities, ensu- deeply rooted in our international customer engineering and testing solutions where they
ds mature advanced eDrives and are focusing re that all our developed products reach mass experience are required most
on 400V and 800V, both for the Chinese and production, accelerating electrification for our
international markets. customers.

Deep understanding of the Off-highway and heavy-duty

As a renowned player in the field of innovative drive technologies, inverters, motors, and software for electric drives. The JV, with
domestic market applications
hofer powertrain makes a crucial contribution to the success of its location in Beijing, is becoming a central hub in a booming
With employees mainly coming from OEMs, With changing emission standards for new he-
the joint venture, providing its extensive technology and know- market segment. Supported by a wide network of suppliers, the
Tier-1s, and other relevant industry areas, the avy-duty trucks powertrains, we are expanding
how resources. Through this strategic partnership, the joint teams are driving development and production forward and can team is highly experienced in automobile and our long-standing expertise by increasingly
venture is empowered to benefit from hofer powertrain's decades already point to several won customer projects before starting powertrain development and application, brin- focusing on commercial vehicle eDrives
ging an excellent understanding of the market
of experience and industry-leading expertise in the areas of operations.
trends and customer needs

40 41
 2 Location Updates Location Updates
2

STRONG TRACK RECORD IN DEVELOPING

EFFICIENT EV POWERTRAINS

ESCHEN LIECHTENSTEIN

”
We are hiring!
Our new location supports our overall hofer powertrain
Since October 2021, our new development and e-mobility center in Eschen,
philosophy and vision with its innovative development Join us to turn visions into efficient and
Liechtenstein, has strengthened hofer powertrain operations with a new team of experts. future-proof drivetrain technologies!
approach. Thanks to their strong expertise, the
This addition of strong know-how and new technologies complements hofer powertrain's
new teams fit seamlessly into our extensive system
product and service portfolio in various disciplines related to electric drive systems. This hoferpowertrain.com/jobs
engineering network. They have been actively helping
location's distinctive electrical engineering expertise ties in seamlessly with the company's
to meet the increasingly stringent requirements of the
objectives around e-mobility and innovation and enables further growth.
automotive industry right from day one.

Philipp MATT,
Head of hofer powertrain Electronics

High competence at a system level Strong industrialization

capabilities
With years of experience in EV powertrain
development, including e-motors, electronics, From designing and concepts of different
The know-how of our engineers and technicians includes
and software, this location has a strong track production lines to process development and
high-voltage systems, multi-level inverter solutions, and record of developing robust and more innova- optimization to quality assurance, we accom-
pioneering winding technologies for e-motors. Additional tive powertrains. The teams are highly skilled pany our customers at every step.

testing, manufacturing, assembly, and industrialization at deploying breakthrough technologies.

capacities cover the entire electric drivetrain, with operating

rooms designed for maximum information security. Various
development environments and numerous protoshops with
high-precision equipment ensure smooth operations. Full scope testing capabilities for Representation of the entire value
end-to-end EV powertrain tests chain
All mechanical components and complete One of the unique characteristics of the faci-
systems can be tested, verified, and approved lity in Eschen is the large in-house develop-
on our test benches and in the electronics ment capabilities and tooling diversity along
laboratories for high-voltage diagnostics. the entire value chain.

42 43
 2 Location Updates Location Updates
2

DEVELOPING FUTURE-PROOF SOFTWARE

BUDAPEST HUNGARY AND HARDWARE SOLUTIONS

The main goal is to intensify development expertise in vehicle

control electronics and software, optimizing communication
between the individual modules, and boosting the overall
system's efficiency.

” With the new development location in Budapest, Hungary, we advance the

technological evolution of hofer powertrain. Here, the team is helping to further expand
our expertise in various disciplines related to Electric Drive Units and the overall portfolio
of products and services. Specialized in software and hardware development with a core
Strengthening of our in-house expertise
in software and hardware development
20 years of software & electronics
experience combined with impulses from
focus on control software and algorithms, we provide technologies that optimally support
hofer powertrain's technological roadmap and thus help accelerate the progress towards happens on an ongoing basis new talents
the electrified future.
In tandem with the locations in Wuerzburg, Graz, and St. Ulrich, the The strength of the new teams lies primarily in their longstanding
new teams of electrical and software engineers have significantly experience in software development for automotive longitudinal
Tamas KRIKLER,,
expanded hofer powertrain's expertise in software and hardware systems, reaching back as far as 20 years within the automotive
Managing Director & Business Unit Leader Software
development, including both application and control software. They industry. At the same time, the new location offers a direct link
form a strong unit in developing future-proof and safe systems. As to the technical university in Budapest, which facilitates a lively
a result, we elevate our in-house competencies in this area to a new exchange of ideas and close networking with up-and-coming
level. Equipped with all essential facilities, electronics laboratories, engineers.
hofer powertrain and necessary test rigs, the new team members took on various
Development Center for Advanced Software and Hardware Systems crucial tasks in many disciplines right from the start.

Superior software engineering Cybersecurity expertise

From the design, development, and calibration We aim to eliminate every security gap in
of functions in the vehicle to the final SOP – complex technical applications and bring the
we develop drive train functions and control most reliable solutions to our customers'
software, considering the entire system. future models.

TISAX® Level 3 Highest quality

Together with several other hofer powertrain We align all methods and processes with
development centers, this location achieved the high standards of functional safety (ISO
TISAX assessment level 3 in 2021, 26262) and now also operate in compliance
demonstrating a high level of information with the requirements of ISO 17025.
security in the shortest time frame.

Hardware safety – an integral part We are hiring!

Our team ensures the highest hardware safety
through comprehensive processes, analyses,
Join us to turn visions into efficient and
and tests. We answer complex questions
future-proof drivetrain technologies!
regarding error behavior, diagnosis, tolerance,
and isolation, and energy capacity. hoferpowertrain.com/jobs
44 45
 2 Location Updates Location Updates

WARWICK UK DEVELOPMENT CENTER FOR

HYBRID AND ELECTRIC HIGH-PERFORMANCE

AUTOMOTIVE FIELD
A team of dozens of highly qualified mechanical, electrical, ny, this service is now also available to our English customers.
and software engineers, the right staff in quality control, Key features of the testing facility include several climate
and project managers lead projects of all caliber to success. chambers with a capacity of 4,000 liters and equipment for
While this location holds strong expertise in developing advanced swelling performance tests. A specially equipped
hybrid and electrified solutions, its connection to the hofer battery cycler allows for regenerative battery cycling,
powertrain teams worldwide brings additional benefits switching on and off, as well as lifetime tests of batteries with
from its multi-nationally available engineering resources, high current. In addition to focusing on battery tests, we are
including capabilities in GaN Inverter development and 800 intensifying our focus on battery developments - from the
V applications. cell to the pack - and our battery innovations in the market to
In 2023, we are bringing our battery testing capability to War- meet customer needs.
wick, England, in response to the steadily growing demand for This expansion is based on our strong core competency, which
battery testing. Inspired by our extensive expertise in Germa- is already available to our customers at other locations.

”hofer powertrain is shaping the future of electrification with

global collaboration and cutting-edge innovations. From Warwick's
advanced battery tests to the McLa-ren Artura transmission design,
we anticipate demands, evolve with agility, and champion the future
hofer powertrain of mobility with unmatched expertise."

Development Center for Hybrid and Electric Drives

Martin MAIER
Managing Director, hofer powertrain UK

Engineering of unique transmission Rapid project delivery up

solutions & electronics to production

With high system competence, we provide significant With hofer powertrain's expansive network, different
benefits and the desired driving attributes with out- development and production scenarios can be covered,
standing performance levels and compact package up to rapid green-field production site development for
envelopes individual needs

Global hofer powertrain ressource Consideration of all safety and

pool incl. strong supplier network regulation standards

With a globally active hofer powertrain group and its Compliance and quality is ensured in accordance with
diversity of experts, we have the right expertise to the latest standards Images:
design all your eDrive innovations hofer powertrain Warwick and Solihull, development and
production of DCT and DHT for high-performance customers

46 47
3 Product and technology updates Product and technology updates
3

EXTREME HYBRID
WITH TOP SPEEDS UP TO...

Electrification of speed within

the hyper car

450 km/h Electrification slowly but surely reaches the performance-driven hypercar world and bears both oppor-
tunities and challenges for engineering teams. This sector sets the bar high, where agile design processes
are essential to achieve exceptional results. Our powerful 8-speed transmission with an e-reverse gear for
weight saving proved that new heights in engineering can be achieved. It was conceptualized, designed,
and produced in series within only four years. During that process, a new powerful design opportunity was

”
uncovered.
We focus on advanced transmissions with electric DNA for high-
end applications, always striving for unprecedented performance
levels while simplifying complexity, increasing cost-effectiveness,
and reducing overall packaging. This new solution is a case in point –
electrified performance for our speed enthusiasts. We challenged the status quo of our last hypercar solution in
2022 and found a new way for numerous adaptation possibilities,
considering future customer demands

Acceleration and performance

through intelligent layout
The development looked for new solutions to support extremely high performance levels, mainly driven by
the desire to increase levels of e-motor power for high acceleration and maximum vehicle speed (above 450
km/h). At the same time, they wanted to shorten the distance between the front transmission flange and
the output shaft to give more freedom in vehicle design. A P2.5 hybrid topology has been designed, moving
the motor to the rear of the transmission, and connecting the drive via the 7th gear. The performance has
been simulated with an e-motor output of 300 kW max. and proved to be a success.
This new P2.5 layout
enables a power split to
deliver high combined
torque levels from the
combustion engine and the
electric motor
Discover all
engineering services
www.hoferpowertrain.com/engineering
48 49
 3 Product and technology updates Product and technology updates
3

hofer powertrain’s continuous development efforts result in a

successful track record of high-performance EDUs
Since the beginning, hofer powertrain has led the way in EV technology,
transforming the industry with our revolutionary Electric Drive Units
(EDUs). Recognizing early on the value of integrating main subcomponents
into a single, compact housing, we pioneered a scalable and 3 L PE
interchangeable design that allows for maximum customization.
While this modular approach is not new anymore, we still aim
to bring a maximum of efficiency into the solutions. Our
approach empowers the future of EVs, meeting diverse GaN
power demands, ensuring an efficient, powerful, ONEBOARD HV BOOSTER
and streamlined solution for every vehicle.
FLW

SINGLE EDU

EDU Nio IP EDU 150-O EDU ONEBOX EDU 800 V BOOST EDU ETA EDU ETA (GAN)

DUAL EDU

EDU RSE EDU TORVEC EDU TORVEC V2 EDU HC TORVEC EDU ETA TORVEC

DHT

TWIN DRIVE DHT High Perf. DHT HP V2

2006 2016 2022 2024 2026

Various EDU power classes for instant

implementation and / or series production
For instance, for the 100-150 kW power class, our ar EDU The ONEBox EDU serves the 200-300 kW class, while for
is designed for over 400.000 km lifetime and optimum the 300-350 kW and above 400 kW ranges, we offer the
efficiency. For the 150-200 kW range, the 800V Boost HCTV EDU and TorVec EDU among other solutions.
EDU is ideal for fast charging and high-power applications.

50 51
3 Product and technology updates Product and technology updates
3

FUTURE PROOF TECHNOLOGY

ALL-IN-ONE HOUSING Most compact all-in-1 800 V+ charging and
Electric Drive Unit driving power

ULTEVATE
800 V BOOSTER EDU 400 V compatibility in Based on modular
ULTEVATE platform
charging mode

Scalable, highly integrated, and package-optimized EDU

featuring the most advanced technologies

This compact EDU solution combines the latest proven optimized continuous power in the motor and up to 25%
technologies,
x such as Form Litz Wire winding in its e- energy loss reduction, making it the most economically
motors and a GaN 800 V technology in its inverter. The beneficial product for various mobility applications.
verifications and simulations of the system have shown

POWER SCALABILITY WITH HV BOOSTER

FORM LITZ WINDING

3-LEVEL INVERTER

800 V BOOSTER
MODE MID HIGH HYPER
Peak power 170 kW 300 kW 360 kW
Cont. power 120 kW 150 kW 250 kW

52 53
 3 Product and technology updates Product and technology updates
3

DISCOVER OUR LATEST

Two separate inverters for
HIGH-COMPACT TORVEC EDU optimal torque control

Our latest design of the successful TorVec EDU is now available.

The new HC TorVec EDU is designed for powerful high-voltage
applications and delivers individual torque to the wheels for
maximum control and safety in any driving scenario.

This EDU combines maximum performance with two electric

motors and two separate gearboxes for each side while being
exceptionally compact.

We introduced a unique water-cooling concept making this

solution extraordinarily robust and reliable.

Highest energy density of a

TorVec EDU

ULTEVATE High voltage capability

HCTV EDU 800 V+

Combined water cooling for

both e-motors and inverters

An innovative EDU layout with two

electric motors and two gearsets
compactly integrated into a single 23.000 to 24.000 rpm Individual torque control for
housing through planetary gear increased driving stability

54 55
3 Product and technology updates Product and technology updates
3

ULTeBEAM
A high-performance electrified
rigid axle for commercial
SPEEDING UP THE ELECTRIFICATION OF vehicles, trucks and SUVs

COMMERCIAL VEHICLES

Built on the architecture of the

conventional rigid axle, this
technology provides a practical,
quick solution in electrification
Designed to advance the electrification of commercial and high performance. By matching innovations
vehicles, the ULTeBEAM solution enables automotive to real customer needs, hofer powertrain
manufacturers a seamless conversion of their existing can achieve the best results through
internal combustion engine (ICE) powered trucks, vans close collaboration.
and other types of light and medium duty vehicles into
battery electric powered vehicles. The modular ar-
chitecture of this solution supports both 400 V and 800
V configurations and provides maximum flexibility for
OEMs and Tier1 customers. This innovative electrified
axle solution consists of a transmission and e-motor duo
connected to an external inverter for increased safety

The solution for high energy-

intensity applications
Modular design Efficient system
With the commercial vehicle market on the rise, de-
Our modular design allows for both 400 V and High performance, efficiency &
mand for electrified and low-emission solutions is ac-
800 V configurations compactness characterize the ULTeBEAM
system celerating, especially for off-highway applications such
as utility vehicles. However, high-energy applications
such as harvesters and snow ploughs present challen-
ges for all-electric operation. The ULTeBEAM solution
overcomes these challenges and promotes sustainable
High safety Maximum flexibility technical progress. The compact solution is designed for
integration into central axles, which is a typical feature
of commercial vehicles with combustion engines today.
Developed for demanding applications and ULTeBEAM is designed for many different
The compatibility allows for easy replacement of the
heavy-duty vehicles, ULTeBEAM enables incre- vehicle classes, from vans to LCVs. In addi-
ased safety even at the highest power levels tion, the system can be adapted to specific old axle with the electric ULTeBEAM axle, thus not only
customer needs simplifying but also accelerating electrification for car
manufacturers.

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3 Product and technology updates Product and technology updates
3

HIGH-SPEED MOTORS MOST EFFICIENT EESM

BOOST EV EFFICIENCY WITHOUT RARE EARTH
The demand for rare earths has grown due to the climate
transition. Their use has brought the necessary efficiency to
electric motors for the automotive industry in recent years.
However, the extraction of these is very laborious, requires
a lot of energy, and the mining is environmentally harmful. High performance without
hofer powertrain has been focusing on the development of compromizing our environment
new engines for some time now, which deliver high perfor-
mance without the use of rare earths – the externally exci-
In the rapidly evolving landscape of electric vehicle While the first strategy may seem intuitive, it presents ted synchronous electric machine.
technology, manufacturers are constantly seeking in- a range of new challenges due to the added weight of
novative solutions to tackle the dual challenge of ran- larger batteries. However, the latter offers a promising
ge anxiety among consumers and the demand for ligh- path for innovation. High-speed electric motors, espe-
ter, cost-effective, and high-performance solutions for cially those capable of operating at more than 20,000
Contactless transformer
OEMs and Tier1. In this pursuit of efficiency, two main
strategies have emerged: increasing the size of battery
rpm, are increasingly taking center stage in the electric
vehicle industry.
Increased efficiency approach to rotor excitation
packs and boosting the speed of electric motors.
New concepts in the development of electric motors
Reduced weight are always on the agenda at hofer powertrain. A current
project is the design of a comprehensive Electric Drive
High-speed advantage Unit (EDU), equipped with an Electric Engine Electronic
Starter Generator Module (EESM), which is also compa-
Safety and reliability tible with future technologies such as the 3-Level (3L)
By increasing the speed of electric motors, their size can be reduced significantly, which leads to a reduction
inverter. This represents a significant interest for the in-
in weight and energy consumption. In this way, electric cars can cover greater distances with the same set of
dustry. We build electric motors that achieve high per-
batteries, which also counteracts range anxiety.
formance levels and make no compromises in terms
of efficiency or weight. A revolutionary aspect of this
development is rotor excitation. We face the technical
challenge of injecting the necessary current to generate
the magnetic field into the rotating motor – this is done
€ Cost reduction using a contactless transformer to avoid friction losses
in the system. It's unique that the rotor doesn't contain
any copper wires. In addition, in case of a failure, the di-
High-speed electric motors require less material use, which in turn lowers the overall cost of the develop-
scharge function is activated, allowing the rotor to self-
ment and more so in series production. This cost efficiency is a key advantage in the competitive electric
discharge, which can, for instance, be achieved with a
vehicle market, where manufacturers are constantly striving to balance performance and price points.
3L inverter. Thanks to the frictionless solution, energy
losses are prevented, thereby maintaining the overall ef-
ficiency of the motor.

Tests & quality control

Developing high-speed electric motors comes with its own set of challenges. It requires specialized test
equipment capable of handling these high-speed electric motors, as well as a range of development skills to
ensure the quality of the product. hofer powertrain promises best results with full-scope testing capabilities.

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 3 Product and technology updates Product and technology updates
3

FORM LITZ WINDING Maximum cost optimization

• Reduced BOM cost
MOST FUTURE-PROOF Furthermore, it uses existing hairpin manufacturing GEN 5 • Reduced invest for
technologies for wiring, ensuring the technology's high industrialization

AND ECONOMICAL TECHNOLOGY maturity level and cost-competitive stance against the
traditional hairpin winding. Even more impressive, the Feasibilitv for mass production

GEN 4
integration of this technology into existing hairpin pro- • Integration into 3in1 system
duction lines prevents "stranded investments", with easy • Design for manufacturing
conversion options for current stator production lines. • Process reliability
This cost-optimized and sophisticated design, which
also features a hairpin connection with two layers and

GEN 3
a no-welding U-Pin, is both easy to automate and offers Redesign & filling factor improvement
a stable, hard formed-wire that enhances production • Winding head reduction
efficiency.. • Oil-cooling

A new winding technology for

stators to increase efficiency
GEN 2
The impressive efficiency and cost-effectiveness of this
and optimize the size of the design are protected by several patents filed by hofer Proof of concept for ASM
powertrain in 2022, underscoring its significant cost
e-motor
and performance advantages, particularly in large series
production.
hofer powertrain´s Form Litz Wire (FLW) Stator Design
outperforms traditional winding technologies like Hair- Basic technology development
pin or Pull-in windings by offering significantly higher Integrated into hofer powertrain EDUs, and in com- GEN 1 • Proof of concept for PSM

25%
continuous performance in electric motors. It achieves bination with our 3L inverter, the technology offers
this superior performance through a combination of additional high cost savings and maximum efficien-
strategies, including the use of highly compressed stran- cy advantages for our customers compared with the
ded Litz wire located in the active part of the motor, a benchmark.
connection with a flat wire known as "FL-Hairpin-Hyb-
rid", and a reduced welding process.
less power loss
in e-motors

20% 25%
cost savings on the higher
e-machine level power density

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3 Product and technology updates Product and technology updates
3

800 V 3 L GaN REVOLUTIONARY MULTI-SPEED

THE NEXT MILESTONE EV TRANSMISSIONS
IN DEVELOPMENT

E-mobility has revolutionized the automotive industry and hofer powertrain

Background and Recent evolution – is proud to be at the forefront of this transformation. One key area where we
are driving innovation is multi-speed technology in electric powertrains.
successful tests the new 3L-POW module
Multilevel inverters play a crucial role in electric drive hofer powertrain is currently focusing on the develop-
applications, especially in the automotive industry. They ment of a 3L-POW module optimized for GaN techno- Advantages hofer powertrain: a pioneer
offer significant advantages such as higher voltages, logy with a high current rating of 600A. This advance is
reduced harmonic losses, and improved NVH (Noi- a major step towards further development and higher in multi-speed transmissions
se, Vibration, Harshness) and EMC (Electromagnetic maturity of the technology and paves the way for its
Compatibility) properties. The superiority of gallium impending mass market launch. The innovative modu- Multi-speed technology offers a range of advantages At hofer powertrain, we have recognized the benefits
nitride-based (GaN) components over traditional sili- le will also be integrated into the latest generation of that make it an attractive option for electric mobility. of multi-speed technology and are already offering so-
con-based components is increasingly being recognized, hofer powertrain inverters. First, it enables more efficient energy use as it keeps the lutions in this area. Our engineers have extensive expe-
which accelerates their adoption. motor in its optimal operating range. This leads to impro- rience in developing and implementing these solutions
Given the market's readiness to adopt this technology, ved vehicle performance and increased range. that enhance vehicle performance and efficiency.
A prime example of this is the newly developed 3-level numerous automotive projects provide valuable insights
(3L) GaN inverter from hofer powertrain. It has proven into the benefits of GaN technology for practical appli- Second, multi-speed technology allows for higher ve- A standout example of our work in this area is the suc-
its ability to increase the efficiency of electric motors cations. The potential of this technology is increasin- hicle speeds. By using multiple gears, the vehicle can cessful development of a 2-speed EV transmission for
and reduce WLTP losses in the driving cycle by an im- gly being recognized and is arousing the interest of the drive at higher speeds without excessively straining a German OEM sports car (More info on page 17). This
pressive 25%. This success leads to reduced cooling industry. the motor. project involved the development of a 2-speed trans-
requirements and improved performance. Additionally, mission with a high axle torque capacity (> 8500 Nm)
the inverter reduces the "loudness" by 25% and shows In particular, in commercial vehicles, motorsport vehic- Third, multi-speed technology improves the driving ex- and an innovative parking lock concept. It combined
similar improvements in EMC performance. les, hypercars, and eVTOLs (Electric Vertical Take-off perience and comfort. It allows for smoother accelera- spur and planetary gear sets and enabled tension-free
and Landing vehicles), the benefits of multilevel inverter tion and provides drivers with more control over the shifting.
technology are evident today. In these applications, the vehicle.
high power demand and reduced sensitivity to inverter Furthermore, multi-speed technology remains a focus
BOM costs (Bill of Materials) have already led to impro- of our future development work. We are committed to
vements in the electric drive system at the vehicle level, continually improving and optimizing our technologies
compared to the 2-level type. to meet the changing requirements of electric mobility.

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3 Product and technology updates Product and technology updates
3

PIONEERING BMS SYSTEMS CELL-TO-PACK ARCHITECTURES

FOR HIGHEST POWER DENSITIES

We take pride in providing Cell-to-pack engineering projects are revolutionizing se includes system and component development using
comprehensive battery the battery industry by focusing on increasing the volu- advanced simulation techniques such as 1-D, CFD and
management system (BMS) metric energy density at the battery pack level while si- FEM. Subsequently, a thorough characterization of
solutions that are uniquely multaneously reducing overall costs. These projects pri- the battery pack is carried out, evaluating the electri-
temperatures, and other parameters. Our services cover oritize safety performance and are designed to reduce cal, thermal, and mechanical properties. Finally, perfor-
designed to meet the most
all phases of the BMS lifecycle, from initial conception the number of necessary components to ensure efficient mance testing and homologation are performed to en-
individual needs of our customers.
and design to software development and safety assu- and sustainable use of raw materials. Furthermore, they sure reliability and compliance with industry standards,
rance. With a particular focus on adaptability, we enable are adaptable for fast-charging applications, making followed by assembly and prototyping to bring state-of-
In vehicle engineering, the BMS acts as an interface bet- seamless integration of existing components into our them highly suitable for a wide range of industry areas the-art cell-to-pack solutions to the market.
ween the vehicle and the electronic components within BMS solutions and vice versa. The expert team specia- and applications.
the battery. It controls functions necessary for the vari- lizes in ensuring optimal performance, reliability, and
ous operating states of the vehicle and continuously mo- safety for battery systems in electric cars of all kinds. To achieve these goals, comprehensive engineering ser-
nitors the battery system for potential errors in voltages, vices are deployed, starting with system development
which includes requirement engineering, system design
and concept studies. The design and development pha-

COMPLETE DEVELOPMENT
1 2

Concept Design
1 2
Requirements analysis Architecture and design • Requirements analysis • System engineering
• Concept studies • Component engineering
• System design • Modern simulation techniques
3 4
Software development Supplier management
3 4

Characterization Testing & admission

Continuous testing and integration

5
Project management and quality control Prototyping and assembly

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3 Product and technology updates Product and technology updates
3

INTELLIGENT BATTERY DISCONNECT UNIT

Centralization battery technology fundamentally changes electric drives –

maximum safety, efficiency and simplicity

The latest centralization innovation has the potential By using the iBDU, automakers and Tier 1 suppliers can
to fundamentally change the future of the automotive significantly reduce their development and component
industry. The so-called "Intelligent Battery Disconnect effort, material costs (BOM), and the number of required
Unit" (iBDU) is an optimized battery safety solution that components – currently, cost savings of over 12% at the
meets global safety standards, reduces battery costs, BDU level and space savings of up to 18% are possible
and significantly increases safety and efficiency in the despite additional integrated safety technology. Tests
system. The iBDU enables functions and control units, and simulations show high potential for twice as much
which could previously not be centralized or only centra- reduction in the near future. The new architecture faci- Efficiency increase
lized with increased effort and risk, to be bundled into litates communication between individual components Failsafe unit
one system, and provides a cost-effective solution that and helps OEMs overcome design hurdles that arise in
reduces the number of components required to drive a current systems due to a large number of communica- Centralized control units and functions
vehicle and improves its performance. tion loops and interactions between control units and Developed for automotive battery systems
components, and many complex interfaces.
The iBDU also offers a new safety dimension in the
high-voltage range, through outsourced and separated
high-voltage lines, standardization of all battery-specific Highest safety ECU-Centralization
safety functions, and highly reliable early detection
of thermal instability of any kind. This ensures that all
standarts
safety requirements and standards are met. Sustainable development and reduction of
Out of the box ASIL interfaces and therefore interaction with
suppliers

~30% ~40% Economical benefits

€

Industrialization

At the overall powertrain level Multi-pack system > 1000 V

Lower costs alone Reduced
on the battery side package size

For all HV batteries

66 67
 WE ACCELERATE THE FUTURE OF 3
Product and technology updates

”
FAST CHARGING SYSTEMS
FROM A CONCEPT TO A MARKET-LEADING TECHNOLOGY Will charging feel like fueling up
or even faster?
Growing demand for highly efficient, high-performance energy storage solutions motivates our battery
experts to think beyond the conventional and translate their ideas into pioneering technologies. What
started as a research and development project has turned into a groundbreaking innovation that opens new
possibilities for a wide range of application areas, from sprint and endurance race cars to high-performance
vehicles to logistics and commercial vehicles within the megawatt-charging sector.

BLUEFIRE BATTERY: FROM 0 TO 80% SOC IN LESS RACE AND HIGH-PERFORMANCE VEHICLES
THAN 90 SEC. – OFFICIALLY VERIFIED

hofer powertrain has developed a fully functioning high- RAPID CHARGING ON THE RACETRACK AND
voltage battery using the latest BMS system on the market and HIGHWAY WITHIN SECONDS
a fast-charging CCS DC wallbox. The system was subjected to a
series of complex tests under load and with real road resistance Initially designed for long-distance operation, this battery is ide-
to verify the concept hypothesis and has exceeded every initial ally suited for 24-hour endurance races, where speed of charge is cru-
expectation. Our hofer powertrain BlueFire battery achieves cial. Its capacity on a smaller scale is 3 kWh and 400 V, with 500 Amps
extremely high cycle stability. By simulating various driving charging capability, allowing up to 20 minutes of running time on a sin-
situations powered by the high-voltage charging station, we gle battery charge. Since the first proof-of-concept (POC), where the
could determine the battery and system functionalities as well battery was installed into a race kart, its scalability for various high-
as the overall performance points of the system. The latest performance applications has been proven, attracting interest from the
measurements confirm the charging curve. The curve shows market. Our engineers are currently working on several upgrades to in-
that the solution charges from 0-80% S0C in less than 90 crease its charging capabilities significantly.
seconds.
Discover our FlashCharge technologies for LMDe
race applications on the next page

LOGISTICS & THE FUTURE STARTED

YESTERDAY

COMMERCIAL VEHICLES The infrastructure investments and

developments of the automotive industry
reflect important movements in charging inf-
RANGE OF APPLICATIONS rastructure for heavy and light-weight trucks,
logistics, and long-distance vehicles. The over-
head charging infrastructure, or the so-called
"in-motion charging", is in the spotlight. In col-
laboration with various universities and key
industry players, hofer powertrain has been
exploring and pushing the boundaries of the
HIGH-PERFORMANCE TRUCKS
RACE CARS currently available systems and proposed
VEHICLES new concepts for a while. With many years of
experience in battery development, we have
For race applications To e-power high-per- Strong transition of truck
the tools and expertise required to bring inno-
up to the formula sports formance vehicles of diffe- and commercial vehicle fleets vative battery and charging solutions in me-
level rent classes into the e-mobility field gawatt charging while leveraging technology
efficiencies.
68 69
 Product and technology updates
3
THE EVOLUTION OF BlueFire

TOWARDS ENDURANCE RACING LMDe

New cell generations for the new purely electric

endurance racing LMDe

Using high-power cells as a basis for our BlueFire battery, the

engineers aim to raise cells' energy density from 46 Wh/kg to
85 Wh/kg to 115 Wh/kg and finally 135 Wh/kg by 2025. This
type of cell proved best suitable for applications requiring
quick charging and discharging of high currents. With the in-
crease in energy density, cell weight is expected to be reduced
to 482 kg compared to the initially available 1415 kg.

Charging 5-85% SOC Radical reduction of cell

within 90 sec. weight and increase of
energy density

Extended cycle live Discharge 40,5 kWh in 10

350 cycles ~ 1000 laps minutes 30 seconds (3 laps)

ROADMAP

Battery Type Battery Type Battery Type Battery Type

BLUE FIRE X1 LMDe X2 LMDe X3 LMDe
2019 - 2022 2022 - 2023 2023 - 2024 2024 - 2025

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3 Product and technology updates Product and technology updates
3

SOFTWARE AS A CENTRAL
INSTRUMENT FOR HIGHEST
CYBERSECURITY

In recent years, hofer powertrain has established itself From 2024, a certified Cybersecurity Management However, the growing importance
as a provider of advanced control software applica- System (CSMS) will be required for all new rolling of electronics in the vehicle
tions and innovative hardware solutions. With a team stock. Tamas KRIKLER, who has been in charge of hofer presents the automotive industry
of professionals who have years of experience and a high powertrain's large software division since autumn 2022, with one of the greatest challenges:
understanding of electrified drives of all kinds, we are emphasises the core focus on maximum cybersecurity
Cybersecurity.
able to develop forward-looking technologies and integ- in accordance with ISO/SAE 21434. In this context, all
rate them optimally with other vehicle components. ECUs and electrical systems are developed with this re-
gulation in mind.

Market trend
Market size in billion USD

3.4

3. 5

2 .4 5. 3

”
3.9

2
0.6 1 1
2020 2025* 2030*
By complying with these regulations and continuously
improving safety measures, hofer powertrain contributes
Cybersecurity hardware components
Cybersecurity-related software development efforts to achieving the goal of the greatest possible driver and
Cyberecurity processes and solutions
passenger safety in the entire vehicle.
*projected numbers

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3 Cooper ations and partnerships hofer AG Cooper ations and partnerships
3

hofer powertrain products

(hpp) Hainachuan hofer powertrain
DESIGN AND
UNIQUE MANUFACTURING CAPABILITIES FOR
SERIES PRODUCTION OF eDRIVES
HIGH-PERFORMANCE DRIVES

The high-performance hybrid dual-clutch transmission by implementing a new technologically complex trans- To address the lately gained rapid technological momen- here, including meticulous validation of systems. These
developed by hofer powertrain for this world-renowned mission concept that combines advanced technologies tum in China the JV focuses on the rapid development advancements are achieved through intensive collabo-
sports car manufacturer was successfully transferred with unique performance. of proven electric motors, power electronics, and rela- ration between 2 partners, experts, researchers, and
into production in 2021. To date, more than 3,000 assem- ted software from the hofer powertrain portfolio, with engineers from various fields. Also, in the beginning of
bled and extensively tested systems have left our mo- Based on the experience acquired, the development and various weight, power classes and densities, to ensure 2024, our Dedicated Hybrid Transmission (DHT) will al-
dern factory. This step was made possible together with production teams of the joint venture are well-equipped optimal performance and efficiency. Not just individual ready be entering mass production, laying the foundati-
ElringKlinger in our joint venture hofer powertrain pro- for joint customer projects and new challenges in the components; complete electric units are also realized on for future hybrid advancements.
ducts in Solihull. Our teams demonstrated strong com- future.
petence and innovation in achieving this ambitious goal

CRRC & hofer powertrain VisIC

SERIES PRODUCTION AND TESTING
FUTURE-ORIENTED
OF ELECTRIC DRIVE UNITS
POWER ELECTRONICS
WITH GaN TECHNOLOGY
”hofer powertrain's development sets
the course for a breakthrough in the
performance enhancement of GaN
The production facility, built jointly by hofer powertrain a comprehensive range of tests for electric axles, inclu- hofer powertrain relies on state-of-the-art chip techno- inverters, which are far ahead of silicon
and CRRC Wuxi, is now operating at full speed. Prepara- ding transmission testing, NVH tests, environmental logies and implements new multilevel power electronics and silicon carbide-based systems in
tion for the series production of the new Electric Drive tests, among others. with the innovative gallium nitride chip technologyD- terms of high efficiencies.
Units (EDUs) have successfully started in 2022. A key 3GaN (Direct Drive D-Mode) from the leading supplier
feature of the joint venture is the in-house test center, for the automotive sector, VisIC Technologies Ltd. The
which is equipped with numerous test rigs. These cover cooperation accelerates the development of next-gene- Ilia BUNIN
ration powertrains.
Senior Product Manager & technical Expert,
VisIC Technologies

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3 Cooper ations and partnerships Cooper ations and partnerships
3

SOQRATES PANEL(hpp): VDA

PARTICIPATION IN THE SOQRATES PANEL ON ASSOCIATION OF THE AUTOMOTIVE INDUSTRY
CYBERSECURITY AND ASPICE

hofer powertrain is among the members of the SoQra- a range of procedures for threat analysis, preventive de- hofer powertrains is a proud member of the German ship in the VDA allows us to shape the future direction
tes working group, which focuses on the dissemination sign, and tests to prevent cyber attacks on vehicles, with Association of the Automotive Industry (VDA), an as- of the automotive industry together with other member
of proven practices in the field of Functional Safety ac- the extension of Automotive SPICE to include cyber- sociation of over 500 companies providing mobility companies and to make a significant contribution to im-
cording to the SPICe model. Through active participati- security practices being a key topic. This collaboration innovations, vehicle technologies and infrastructure. proving environmental compatibility and the sustainable
on in the working group, the teams have access to the allows hofer powertrain to always stay up-to-date with As a leading provider of innovative drivetrain systems, future of mobility.
latest findings and best practices in the field of practical current technology and offer their customers the safest we share the Association's mission to achieve climate-
implementation of Functional Safety standards. In addi- solutions in the field of drive technology. neutral mobility by no later than 2050 and significantly
tion, there is a particular focus on the topic of cyberse- contribute to this goal by focusing on the development
curity, taking into account new standards that describe of electric drives and future technologies. Our member-

D-SEe FELSS
DIRECT SUPERFAST CHARGING FORMING A COMPLETE GEAR WHEEL
FOR THE ELECTRIC VEHICLE WITH A SINGLE TOOL
FOR MAXIMUM EFFICIENCY IN MANUFACTURING
As part of the research project "Direct Superfast Char- Voltavision have analyzed and optimized the entire
ging for Electric Vehicles", the participating cooperati- energy flow chain from the power grid, through the
on partners developed a new charging technology and charging electronics and charging cable, to the vehicle
a vehicle prototype to be able to store the necessary battery over four and a half years of research work. In a collaborative partnership with FELSS, a thorough manufacturing attempts, successful results have been
energy for a true 400 km range in just 15 minutes. The examination of the axial pressing of running gears and achieved, which were presented in 2023 on the most re-
aim of the research project abbreviated "D-SEe", funded external running gears with helix angles has been per- nowned technology stages in Germany by FELSS. These
by the Federal Ministry for Economic Affairs and Climate formed, where it is no longer necessary to pre-mill the advances offer high efficiency and significant economic
Protection, was to reduce the charging time for 400 km Supported by: gears. FELSS, a recognized specialist in forming tech- benefits in production that can be trailblazing for the
of real driving performance to 15 minutes. The partici- niques, has developed a groundbreaking technology entire industry. In collaboration with FELSS, hofer po-
pating cooperation partners hofer powertrain, Bochum that allows for a helical gearing with helix angles greater wertrain emphasizes its motivation and proactive par-
University of Applied Sciences, innolectric, Keysight than 20 degrees. Together, we have driven innovation ticipation in developments that advance engineering
Technologies, Sensor-Technik Wiedemann (STW), and in gear manufacturing based on customer projects with projects and ensure the industry's future viability.
renowned high-performance automotive manufactu-
rers by providing engineering drawings and the right
material for the investigations. Since 2022, after several

76 77
4 Global presence Global presence
4

hofer powertrain
GLOBAL PRESENCE
EVENTS, SPEECHES, PUBLICATIONS

In the past year, hofer powertrain has significantly With our innovative technologies, patented solutions, At a time when almost every car and commercial vehic-
Webinar
strengthened its global presence and elevated its ex- and strong roots in the drive development business, we le manufacturer is switching to electric drive, the deve-
pertise to a new level. Not only at renowned events in are clearly at the forefront in many areas. The exchange lopment and design of traction motors is in an explosive
German-speaking countries, but also at trade fairs and provides space for a deeper understanding of the cur- phase.
conferences in the USA, UK, Japan, China, and many rent challenges and trends in the market and active in-
other countries, our engineering experts have demons- fluence on the shaping of the mobility of the future. This 60-minute webinar from the editors of Automotive
trated in lively discussions around the topic of sustai- Engineering will explore what is top of mind for pow- SAE Webinar: Traction
nability and efficiency of drives how these goals can be ertrain engineers and developers to maximize efficien-
Motor Innovations for
achieved. cy and performance while offering product differentia-
tion as the electric vehicle market expands. Passenger and Commercial
Electric Vehicles
The technical presentation is followed by a Q&A sessi-
Numerous publications in respected trade on for the audience and the presentation will stay on-
journals and in the form of scientific papers line for the coming 12 months to be shared with indust-
have significantly increased the interest of Register
the international industry. ry partners and teams.
within 2
seconds!

”
Our mission for this
increased presence is to
make a lasting impact on
the world of EV powertrain
Stay up to speed!
The most important press
releases, latest technologies,
innovations and patents at a
glance.
technology – in the region
and globally.

78 79
4 Global presence Global presence
4

Don't miss any technology, service, or product

update. We regularly share the latest hofer
powertrain news and innovation stories.

NEWS

80 81
hofer.de

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