Smart Bearings: Boosting EV Efficiency and Performance

In an exclusive interaction with Thiruamuthan, Assistant Editor at Industry Outlook, Alagesan Thasari, Director & Head of Automotive Business at SKF India, discusses the role of smart bearings in enhancing electric drivetrain efficiency. He explains how these bearings reduce friction, enhance thermal stability, support higher speeds, and lower maintenance costs while improving durability and efficiency. With over two decades of experience in the automotive, rail, IT, and consulting sectors, Alagesan Thasari is a seasoned leader. He specializes in business strategy, product development, supply chain, and engineering, with expertise in managing end-to-end operations.

As India’s high-performance EV market grows, how are smart bearings, particularly hybrid and ceramic types, improving efficiency in electric drivetrains and motors?

As India’s high-performance EV market expands, drivetrain efficiency, reliability, and energy optimization have become critical priorities. Smart bearing technologies such as hybrid and ceramic variants play an important role in addressing these needs by reducing friction, improving thermal stability, and enabling higher operating speeds within electric motors and e-axles. For example, SKF’s ceramic bearings, which use ceramic rolling elements, allow motors to run faster and more efficiently while extending service life.

Specialized deep groove ball bearings are engineered to minimize friction and energy loss, directly contributing to longer vehicle range. Additionally, solutions like conductive brush rings protect bearings from electric current leakage, enhancing motor reliability and durability. Together, these innovations support smoother, quieter performance, better thermal management, and improved overall drivetrain efficiency—key requirements for delivering the range, safety, and long-term reliability expected from modern electric vehicles.

With the rise of EV adoption in India, how do smart bearings contribute to reducing the long-term maintenance costs and downtime in critical electric vehicle components, like motors and gearboxes?

Smart bearing technologies help reduce long-term maintenance costs and downtime in EV motors and gearboxes by improving durability, efficiency, and operational reliability. To give an example, SKF’s advanced bearing and sealing solutions are engineered to reduce friction and energy loss, which lowers wear and extends component life.

Ceramic bearings enable electric motors to operate at higher speeds, more efficiently, and for longer, reducing replacement frequency. Additionally, the SKF Conductive Brush Ring protects bearings from electric current leakage, preventing premature damage and unexpected failures. Combined with advanced lubrication, thermal management, and longer-lasting, remanufacturing-ready designs, these solutions support extended service intervals and more dependable performance. This helps workshops and fleet operators minimize breakdowns, reduce maintenance interventions, and lower total cost of ownership across critical EV drivetrain systems.

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Considering India’s cost-sensitive EV market, how are manufacturers integrating smart bearings into powertrains without significantly increasing production costs, and what cost-saving measures are they employing?

In India’s cost-sensitive EV market, manufacturers integrate smart bearings into powertrains by focusing on modular, efficient, and scalable E-powertrain solutions that balance performance with affordability. SKF’s E-powertrain offerings include a range of low-friction bearings and components designed for electric and hybrid vehicles that raise energy efficiency, enable compact designs and simplify assembly without significant cost increases. This aligns with SKF’s broader strategy to reduce friction and energy loss in EV motors and drivetrains, extending service life and lowering wear-related costs. Additionally, SKF’s focus on longer-lasting, energy-efficient and remanufacturing-ready designs supports extended maintenance intervals, helping OEMs reduce downtime and lifecycle cost. Localized manufacturing, multi-application platforms for ICE, hybrid, and EV powertrains, and advanced lubrication expertise further help contain production costs while delivering high value to cost-conscious Indian EV makers.

As India pushes for greener manufacturing, how do smart bearings help reduce energy consumption and CO2 emissions in electric vehicles, particularly in high-demand sectors like urban mobility?

As India advances greener manufacturing and sustainable mobility, smart bearing technologies play a direct role in lowering energy consumption and COâ‚‚ emissions across electric vehicles. SKF’s solutions are engineered to reduce friction and energy loss, which improves drivetrain efficiency and allows motors and e-axles to deliver more output with less energy, directly extending range and lowering overall power demand. For high-duty urban mobility applications such as two-wheelers, passenger vehicles, and fleet operations, SKF offers advanced bearing and sealing solutions for e-motors and integrated drive units, designed for higher speeds, thermal stability, and long service life, ensuring consistent efficiency under frequent stop-start conditions. Additionally, energy-efficient, longer-lasting and remanufacturing-ready designs support reduced material use, fewer replacements, and lower lifecycle emissions.

By combining friction reduction, durability, and sustainable design, companies like SKF helps OEMs cut both energy use and carbon footprint across the EV ecosystem.

In response to the demand for lightweight and efficient EVs, how are manufacturers in India using smart bearings to reduce the weight of drivetrains while maintaining performance and durability?

In response to the demand for lightweight and efficient EVs, manufacturers in India are redesigning bearing systems to lower drivetrain mass without compromising durability or performance. This includes the use of light-weight materials and non-metallic bearing cages that reduce overall bearing weight in high-speed applications, helping decrease rotational inertia and improve motor efficiency.

Companies are also adopting integrated and compact bearing units that combine multiple components into a single design, reducing part count and system weight, which simplifies assembly while maintaining load capacity. In addition, sensor-enabled bearings that provide real-time operating data for performance optimization and diagnostics allow engineers to fine-tune designs and eliminate excess material. Together, these smart design strategies enable lighter, more energy-efficient EV drivetrains while preserving reliability and longevity.

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Looking ahead, how do you foresee the integration of smart bearing technology in India’s EVs evolving, particularly in terms of predictive maintenance and performance monitoring?

Looking ahead, smart bearing technology in India’s EV ecosystem is expected to evolve from purely mechanical components to more connected, data-enabled solutions that support predictive maintenance and performance optimization. In this space, SKF already combines its core expertise in bearings with condition monitoring solutions and services to reduce friction, enabling smarter, more efficient vehicle systems.

Globally, SKF is focused on driving digital transformation and data-driven decision-making across its aftermarket network, preparing workshops and service partners for more proactive, diagnostics-led maintenance. Additionally, the company is developing a digital ecosystem that supports real-time insights and service accuracy, helping detect issues early and reduce unexpected downtime. As EV adoption rises, these capabilities will allow manufacturers and service networks to move toward predictive care, improving reliability, extending component life, and lowering total cost of ownership across India’s evolving electric mobility landscape.