With the shift to electric mobility, the demands on mechanical drive components are also increasing significantly. While formerly designed primarily for robust power transmission in automobiles, gears these days have to do considerably more: they should run quietly, operate with minimal friction losses, and at the same time transmit maximum rotational speeds in the smallest of spaces. Electric motors leave no room for inaccuracy. Any imbalance, any slight backlash is immediately noticeable – and this is precisely what poses new challenges for the entire automotive industry.
Attention is therefore focusing on the topic of NVH (noise, vibration, harshness). In the field of electric drives, in particular, optimized gearing is not only desirable but essential. The automotive industry must also increasingly address sustainability requirements. What is needed are materials that can be processed efficiently, are lighter, and recyclable. Manufacturing itself must also become more energy efficient, reflecting a clear trend in electric mobility that covers all areas of automotive production – from development to traceability.
Hänel Precision Gears offers decades of experience in the manufacture and development of precision gears, focusing squarely on the requirements of electric mobility – both technically and economically. As a development partner, Hänel Precision Gears supports its customers from the initial concept to series production approval. This expertise makes Hänel Precision Gears a strong partner for suppliers and manufacturers who want to break new ground in electric mobility. No off-the-shelf products – but precisely adapted gears for modern vehicle concepts. Development expertise, manufacturing know-how, and service blend seamlessly with each other. Hänel Precision Gears is therefore actively contributing to the future of the automotive industry – with solutions that deliver impressive benefits both in terms of technology and cost-effectiveness.
Reliability, precision, and collaborative development – that’s the standard Hänel Precision Gears demands for every project. Our manufacturing is designed to meet the latest requirements in the automotive industry: flexibly, precisely, and economically. We focus on the specific needs of our partners in the automotive industry. Whether you want to develop a prototype, organize a small production run, or continue developing an ongoing series production project – we are there for you. With more than 30 years’ experience in the industry, short decision-making channels, and a team that gets results. Talk to an expert. Together, let’s create gear solutions that make your drive concepts precise, quiet, and efficient – ready for the future of mobility.
The requirements for gears in electric drives differ fundamentally from those for conventional transmissions for combustion engines. Electric motors operate at significantly higher rotational speeds and are extremely smooth-running. This means that any mechanical malfunction is immediately apparent, both audibly and functionally. A slight, unnoticed backlash or minimal imbalance, which might go unnoticed in a combustion engine, becomes a problem here – especially in vehicles in the premium segment, where customers demand absolute smoothness. Lightweight construction is also a crucial issue. Every kilogram saved contributes to efficiency. Every gram counts in electric mobility – particularly in terms of range and carbon footprint. Materials must therefore not only be lightweight, but also durable. Geometries are therefore becoming more complex, development cycles shorter, while requirements for dimensional accuracy are constantly increasing. What makes it even more challenging is that electric motors deliver their full performance virtually instantaneously. This means spontaneous load changes, strong acceleration torques, and high continuous loads. Gears have to meet these demands – and do so consistently. The automotive industry needs solutions that are precise, robust, and economically viable. In addition, many original equipment manufacturers expect a comprehensive understanding of development and quality from their suppliers – a competency Hänel Precision Gears has been demonstrating in the automotive industry for years.
Manufacturing technologies for gears in the automotive industry
The production of modern gears for use in the automotive industry is extremely complex. Precision is essential – especially with large production volumes. The individual machining steps must be perfectly coordinated. Every process affects dimensional accuracy, surface quality, concentricity, and noise characteristics.
- Turning: Creates precision-machined raw parts for further processing
- Gear cutting: Hobbing or shaping – depending on the component and requirements
- Internal broaching: For complex internal geometries and compact designs
- Internal and external cylindrical grinding: Ensures precise dimensions and running accuracy
- Gear flank grinding: Reduces noise, optimizes power transmission
- Laser marking: Supports traceability and quality assurance
Consistent quality assurance, modern measurement technology, and digital production planning ensure that the gears are manufactured to the highest standards, even in series production. This is essential for the automotive industry – as are shorter response times for development and customization.
As the automotive environment becomes increasingly globalized and dynamic, these manufacturing standards offer a decisive competitive edge.
Minimizing noise and vibration in electric vehicles
Electric drives require even greater optimization of mechanical components. Gears have a significant influence on what is known as NVH behavior (noise, vibration, harshness) – in other words how loud, quiet or disruptive a vehicle sounds.
- Precisely ground gear flanks enable smooth, quiet operation
- Clean surface finishes prevent localized friction peaks and wear
- Minimal profile deviations counteract vibrational excitations
- Optimized gear geometries ensure stable power transmission
This is critical in electric mobility – because every disruptive noise is more noticeable due to the absence of engine noise. Gears are key to the perception of quality, especially in high-end vehicle classes. Precision manufacturing measurably improves the driving experience. The future of the automobile will be more demanding not only electrically, but also acoustically – with precise requirements for each individual component.
Energy efficiency thanks to intelligent gear design
Efficiency is paramount in electric mobility. Every percentage point of efficiency determines range, charging cycles, and running costs. Gears play a central role here – because they transmit power, but also generate losses in the process.
Intelligently designed tooth shapes significantly reduce these losses. An optimal flank contact line, precisely calibrated profile modifications, and suitable center distances ensure low-friction power transmission. Meanwhile, the use of cutting-edge lubrication concepts specifically minimizes friction and reduces thermal load.
In short: intelligent gear designs play a direct role in increasing efficiency in motor vehicles. They make modern drives more powerful – without increasing resource consumption. And this is precisely what the automobile industry demands of its suppliers. In an era where energy savings and CO₂ reductions are key requirements, gear design plays a strategic role.
