Leadrive Technology has moved into mass production of its EV0062 hybrid dual motor controller, bringing into focus a design that incorporates a dual-channel water-cooled aluminium capacitor to manage thermal performance under demanding conditions. The unit, confirmed on March 23, 2026, is being integrated into Schaeffler’s next-generation DHT assembly and will support both plug-in hybrid (PHEV) and hybrid electric vehicle (HEV) platforms for a major European automaker.n

Production has initially started with a plug-in hybrid platform, targeting multiple B-segment vehicles. The controller is designed to serve across both PHEV and HEV configurations, with a platform approach that enables more than 95 per cent parts commonality between the two.

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At the centre of the system is Leadrive’s proprietary double-sided water-cooled OreoPACK power module. By combining double-sided cooling with coreless current sensors, the company has achieved a compact design that meets corporate EMC Class 5 standards. The module itself is built using a transfer molding process, reducing its size to one-ninth of conventional encapsulated modules while maintaining durability across more than 440,000 rapid power cycles within a temperature range of 65°C to 185°C.

Thermal management remains a key feature of the design. The power module, measuring 200mm in length and 110mm in both width and height, integrates the aluminium capacitor within a dual-channel water-cooling system. This setup is capable of keeping core temperatures below 100°C even when operating in ambient conditions of up to 120°C.

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The development timeline has been relatively quick. Work on the project started back in 2021, before moving into a formal programme in December 2023. By October 2024, the controller had already cleared production approval, with the overall validation cycle completed in about 13 months.

Testing was carried out under a range of operating conditions to check durability and performance. The system went through over 1,200 temperature cycles, from -40°C to 120°C, adding up to more than 3,000 hours under load. It was also exposed to vibration, humidity and temperature shocks before being tested again under working conditions. EMC checks were done at an in-house facility and met the required TL81000 Class 5 standard. The development followed ASPICE processes and reached CL2 certification in January 2026.

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Manufacturing has been set up at Leadrive’s Pinghu base, where a dedicated line has been installed for the EV0062. The facility uses helium leak detection systems with very high precision. During the initial production phase, each unit is put through a two-hour high-temperature test at 95°C under load to ensure consistent performance before it is released.