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电机

适用于各种全电动或混合动力应用的尖端电动机械:设计和开发,并不断进行测试和优化
hofer powertrain offers end-to-end expertise in electric motor development — from concept and simulation to testing, validation, and industrialization. The portfolio covers all e-machine types with advanced winding technologies, direct oil cooling, and ultra-high-speed designs. Whether for passenger cars, commercial vehicles, or hypercars, hofer powertrain delivers cutting-edge solutions with maximum efficiency, power density, and scalability.
From pre-development to series maturity – engineering expertise across all topologies and use cases:
  • Development of IM, ASM, PSM, EESM, and AFM architectures
  • High-speed e-motor designs with integrated oil cooling for maximum thermal stability
  • Lightweight, compact solutions with optimized end-windings and superior power density
  • Full in-house prototype build and validation (A/B/C phases)
  • Industrialization readiness, including supplier coordination and process ramp-up for mass production
Testing, validation, and benchmarking: Confidence through data and measurements
  • In-house testing from prototype to production for all e-machine types through A/B/C-sample stages.
  • Benchmarking different technologies, i.e. comparing a PSM Hairpin (800 V, ⌀280 mm, 900 Nm) with a PSM FLW (around 800 V, ⌀235 mm, 500 Nm).
  • Test bench validation (I.e. peak power in the range of 300 kW, torque above 300 Nm, and continuous power exceeding 180 kW) under controlled conditions.
  • Efficiency mapping (I.e. up to +84% continuous torque and +20% shaft speed improvements wirh Form Litz Wire compared to Hairpin; peak efficiencies over 96%).
  • Cost benchmarking revealing savings potential (I.e. up to 18% BOM reduction by shortening active length)
New winding technologies for higher efficiency
  • Form Litz Wire (FLW) winding with copper fill factors up to 65%, significantly reducing AC and PWM losses
  • Up to +84% continuous torque improvement and 25% more continuous power output compared to hairpin winding
  • FLW designed for scalability, using existing hairpin manufacturing infrastructure
  • Reduced BOM costs by up to 23% due to shorter active lengths and less material use
  • Benchmark results verified through OEM and Tier 1 projects across premium segments

Performance leadership for demanding applications

PSM with FLW winding:

  • Peak power of 380 kW
  • Max speed of 25,000 rpm
  • Torque density >20 Nm/kg, power density >16.5 kW/kg

EESM with brushless excitation:

  • Rare-earth-free, low drag losses, switchable field current for efficiency
  • Improved thermal stability and cost-saving potential (smaller battery, no disconnect unit)

Axial flux motors (AFM):

  • Extremely compact design with torque density scaling by D³
  • Perfect for hybrid systems with high continuous power and minimal packaging

Advanced & innovative cooling strategies

We develop bespoke cooling solutions tailored to customer demands, backed by vast expertise in high-performance thermal management:

  • Direct rotor oil-spray: Efficient cooling for high-speed rotor and magnets.
  • Stator direct oil cooling: Increased continuous power via direct winding cooling.
  • Combined cooling: Water-jacket and oil-spray systems for maximum efficiency.
  • Internal channel cooling: Slot and end-winding cooling for high current densities.
  • Axial cooling (AFM): Optimized oil cooling for compact, high-torque axial flux designs.
Seamless integration with the system in mind
  • E-motor integration with inverter, gearbox, and cooling systems.
  • Support from concept to vehicle-level validation for customer-specific architectures.
  • Packaging, harness design, thermal management, and functional safety expertise.
  • Custom mechanical, electrical, and thermal interfaces for each project.
  • Proven collaboration with premium OEMs and Tier 1s from prototype to series.

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