Electromagnetic actuators in electromobility: key technology for precise control systems

Electromobility is transforming not only drive systems, but also the braking, steering, and cooling systems of modern vehicles. With the elimination of traditional combustion engines, new requirements for precision, safety, and efficiency are emerging requirements that are increasingly being met by electromagnetic actuators. These magnetic actuators, often referred to as magnetic actuators or solenoids, are now indispensable for numerous functions in electric vehicles.

With the sharp rise in the number of electric vehicles, the importance of precise, compact, and energy-efficient actuators is increasing massively. Electric vehicles are increasingly relying on brake-by-wire, steer-by-wire, and active thermal management systems, in which magnetic linear drives perform crucial movements:
 

• Opening or closing valves to control coolant.
• Modulating brake pressure without a hydraulic connection.
• Triggering locks in charging ports or battery modules to ensure safety.
• Switching flaps and bypass systems in thermal management.

Electromagnetic actuators offer advantages such as fast response, high switching forces in a small installation space, resistance to vibration and temperature, and a long service life – criteria that are essential in electromobility.

The requirements for magnetic actuators in electromobility differ from classic applications:
 

• Temperature resistance: Application ranges from -40 °C to +150 °C require high-quality insulation materials and thermal optimization.
• Miniaturization: Compact designs are crucial in order to fit into the confined space of modern EV architectures.
• EMC and high voltage: 400–800 V systems require special shielding and safe isolation.
• Service life: Millions of switching cycles without loss of performance are a standard requirement in safety-critical systems.
• Standards and certifications: ISO 26262 (functional safety), UN R100 (high-voltage safety), and other industry-specific standards must be met.

Increasing electrification is giving rise to new areas of application: active aerodynamics (movable spoilers and cooling air flaps), hydrogen and hybrid architectures, and vehicle-to-grid functionalities are opening up additional areas of application for magnetic linear drives. Studies expect annual growth in the market for electric actuators in the automotive sector to exceed 8% until 2032 (Global Market Insights, 2023).

Electromagnetic actuators – whether as lifting magnets, locks, or linear drives – are key technologies in electromobility. They enable precise control in braking, steering, and cooling systems, secure high-voltage batteries, and optimize charging processes. With the rapid growth of the e-market, the demands for miniaturization, robustness, and energy efficiency are increasing—while at the same time offering opportunities for innovative solutions and customer-specific developments.

1. IEA - Global EV Outlook 2024: https://www.iea.org/reports/global-ev-outlook-2024/outlook-for-electric-mobility
2. MDPI - Research on Brake-by-Wire Systems: https://www.mdpi.com/2076-0825/9/1/15
3. Electronics Weekly - EV magnetic actuators trend 2023: https://www.electronicsweekly.com/news/electric-vehicles-magnetic-actuators-2023
4. Wikipedia - Steer-by-wire basics: https://en.wikipedia.org/wiki/Steer-by-wire
5. Global Market Insights - Automotive Electric Actuators Market: https://www.gminsights.com/industry-analysis/automotive-electric-actuators-market

Why is electrosmog a problem in electric cars?

Electromagnetic fields (EMF) are generated in electric cars by high-voltage cables, battery management and electric motors. These fields are usually below the legal limits, but can cause concerns for sensitive people. The issue only becomes critical if continuous exposure in the interior is not sufficiently shielded.
 

How can I protect myself from EMF in my electric car?

The main focus here is on effective shielding such as conductive cable sheathing, closed metal housings (Faraday cage) and optimised cable routing in accordance with EU standards.
 

What is the role of electromagnets in electric vehicles?

Electromagnets precisely control valves, switching elements or clutches in high-voltage systems - for example in braking, cooling or energy management - and thus guarantee fast and reliable functionality with high power density.
 

What advantages do proportional solenoids offer over standard switching solenoids?

Proportional solenoids enable stepped or continuous force or displacement adjustment - for example in hydrogen control or cooling - and therefore offer finer controllability than simple on/off switches.
 

What requirements do Magnetbau Schramme electromagnets meet for e-mobility?

They impress with customised precision, fast development cycles, high in-house production depth and absolute quality standards such as ISO 9001 and IATF 16949 - essential in safety-critical mobility systems.
 

In what way are electromagnets sustainable components in e-mobility?

Electromagnets help to make systems more efficient - for example through precise control during charging or energy management - and therefore contribute to the overall energy efficiency of electric drive systems. 
 

Are electromagnets in e-mobility reliable under extreme conditions?

Yes, thanks to robust designs certified to IATF 16949, the components are reliable even under pressure, heat or changing environmental conditions - such as those that occur in vehicle operation.