Shaping Transformation Successfully

According to a study by RWTH Aachen, the trend towards integrated drive units is gaining ground, with motor, gearbox and power electronics increasingly designed as a compact, integrated structure. This reduces weight, interfaces and material requirements. Innovations are enabling lighter components, improved stator cooling and higher motor speeds to boost efficiency. Power electronics in drive inverters are already close to optimal, yet SiC and GaN transistors offer advantages in partial load operation.

In parallel, on-board voltage is rising from 400 V to 800 V and, in the future, up to 1,200 V and even 1,700 V. This simplifies faster charging processes, as the conductor cross-sections of the charging infrastructure and the DC cabling within the vehicle can be reduced. However, this requires necessary adjustments in the design of drive inverters, where multilevel topologies in particular prove advantageous. Software is also gaining importance in electric powertrains as a factor for control and connectivity, enabling data-based optimisation, predictive maintenance, and personalised driving experiences. Alternatives such as hydrogen fuel cells are becoming more relevant, especially in heavy-duty transport. Advances in batteries – particularly solid-state, lithium-sulphur, and metal-air technologies – promise greater range, improved safety, and shorter charging times.

Today, production vehicles with SAE Level 3 “highly automated driving” are already on the roads. As a reminder: there are five levels in total, with Level 5 representing fully autonomous driving. Automation – but also e-mobility and mobility services – is made possible above all by software. It is becoming the core element of modern vehicles, unlocking entirely new opportunities for innovative functions, differentiation, and improved functional safety. Car manufacturers are enriching their vehicles with services that offer new opportunities for driver and passenger experience, such as ADAS features. Modern vehicles can incorporate up to 100 control units, with software amounting to around 100 million lines of code. This poses significant challenges for the automotive industry, particularly in managing complexity and enabling over-the-air updates throughout a vehicle’s lifecycle. Future models are increasingly based on high-performance computers (HPCs), zonal architectures, and modular software solutions.

This SoC can also integrate specialised computing structures optimised for artificial intelligence. AI algorithms help vehicles analyse traffic situations and make decisions. The centralised architecture simplifies the vehicle’s electronic design, reduces weight, and increases efficiency. In addition, this new approach enables simplified over-the-air updates of vehicle functions.

The main advantages of eFuses are their flexibility and their self-resetting capability, which eliminates the need for user intervention. Beyond basic circuit protection, they provide numerous additional functions such as overcurrent protection, diagnostics, and communication capabilities (e.g. CAN, LIN).

LEDs are revolutionising automotive design by enabling unprecedented freedom of design thanks to their small size and high energy efficiency. Exterior lighting combines the classic role of illuminating the surroundings with the communication of brand and image. Ambient lighting enhances the driving experience, increases safety, and reflects personal style. Voice-controlled elements, smartphone app integration, and AI-driven lighting adjustments are becoming increasingly common. Interior lighting not only creates a personal feel-good atmosphere, but also becomes an integral part of driver assistance systems (ADAS), for example by providing visual warnings.

Shared mobility, in particular, is gaining decisive momentum: according to a survey by McKinsey, 40 percent of respondents now use multiple mobility options, including environmentally friendly alternatives such as e-bikes. In addition, 20 percent state that they are considering replacing their private vehicles with other mobility options within the next ten years.

The key to this lies in modern vehicle electronics, which enable the integration of GPS, remote access (e.g. via app or digital car key) and real-time fleet management. AI-supported analysis of vehicle and usage data allows for better resource planning, increased efficiency and predictive maintenance, thereby improving the reliability of shared vehicles. Assistance systems, facilitating sensor-based automation up to autonomous driving, further support the realisation of shared mobility solutions. Electrification also plays a vital role: it reduces operating costs, improves environmental performance, and fosters sustainable urban transport.