Tailor-made assembly technology for autonomous driving
Schaeffler Special Machinery implements scalable production line for innovative e-axle system. The mobility of the future is electric, autonomous, and highly complex in terms of production. Schaeffler Special Machinery has developed a scalable assembly line for the production of a pioneering 4-in-1 electric axle for a leading US company in the field of autonomous mobility solutions. The solution is being developed at the Herzogenaurach site and will serve as the basis for planned large-scale series production.
Future-proof assembly line for urban passenger transport
The project partner develops fully electric, driverless vehicles specially designed for inner-city passenger transport. At the heart of the vehicle are two highly integrated electric axles that combine the motor, converter, transmission and decoupling unit in a compact system. The aim was to create a production line that meets the highest technological requirements – with maximum flexibility and a clear focus on scalability.
Flexible assembly system with growth potential
The newly developed assembly line is designed for an annual output of 20,000 units and can be expanded to up to 70,000 units with minimal effort. The system combines manual and semi-automated processes and easily meets all the essential requirements for modern drive assembly:
- Technical cleanliness: e.g. through ionised air purification
- ESD protection: implemented throughout for all sensitive components
- Sustainable process chain: efficient, resource-saving, scalable
- Digital control: via the proven Schaeffler smart.control control system
Special emphasis was placed on the modular design of the line. This is a key advantage in terms of efficiency, adaptability and future-proofing. All workstations are designed according to a uniform and standardised structure. The individual stations can be individually configured with freely combinable process modules – entirely according to product requirements or process progress. This enables faster commissioning, shorter set-up times and investment security.
Our assembly line focuses on maximum flexibility: in a dynamic market environment, our project partner is thus ideally prepared to respond quickly to changing customer requirements. Future versions of the E-axis can be manufactured on the same system without any problems. This is achieved by the innovative transport system, which allows the individual stations to be approached in any number and sequence and with any product orientation.
Global engineering expertise combined
A key factor in the project's success was the close cooperation between various Schaeffler locations: equipment and technologies from Kysuce (Slovakia) and Taicang (China) were specifically integrated, for example for rotor/stator assembly, leak testing, gap filler application and oil filling. The use of proven technology minimised risks and significantly reduced development times, while maintaining high plant stability and process quality.
Holistic engineering: From vision to reality
From conception to layout and material flow simulation to commissioning of the stations at Schaeffler's Herzogenaurach site, Schaeffler Special Machinery took care of the entire implementation during the course of the project. As a result, the production line offers
- high technical availability (98%)
- precise time specifications for the execution of manual and automated processes
- intuitive worker guidance
- end-to-end system integration
Ready for take-off – ready for the future
This line not only provides an innovative solution for the powertrain of autonomous vehicles, but also serves as a powerful example of how Schaeffler Special Machinery is actively contributing to the mobility revolution with state-of-the-art assembly technology.
October 2025
