ZF presents new e-drives for passenger cars and commercial vehicles

Ethel Walsh

ZF is presenting new electric drives for passenger cars and mild industrial vehicles. This most up-to-date technology of e-drives innovations ability density and vitality efficiency due to quite a few improvements at both of those the component and program amount. These involve the compact design and style of the drives, electrical power electronics, and a resource-saving use of components, which also helps make the generation of the drives a lot more sustainable.


ZF’s new electric powered travel

With their modular idea, the new ZF e-drives help automotive companies in customizing the more electrification of their complete model vary. For close shoppers, the new systems present increased performance, extra ability, and shorter charging instances.

ZF’s new era of electrical drives is dependent on a modular overall notion with built-in electric powered motor, inverter, transmission, and software. With its superior degree of interface abilities and know-how for driving procedures, ZF software engineers can meet shopper prerequisites completely. Nonetheless, the Group will also offer you the modern components individually, on which its individual procedure solution is based mostly.

Thanks to subtle inside interfaces, the new, particularly compact style allows system or ingredient variations to be designed with minor energy. In addition, the style has quite large structural rigidity, which enables superior sound habits.

—Dr Otmar Scharrer, Head of Enhancement for Electric Generate Systems

The new technology of ZF e-drives will be available on the current market as a total method starting off in 2025 ZF will carry particular person elements into collection generation earlier. The subsequent improvements at element degree make their contribution to the highly developed overall program:

  • Electricity electronics regulate the balancing act involving a superior degree of component uniformity and high adaptability. The individualization can take location at the chip amount: A discretely structured ZF inverter is designed with personal electricity semiconductor switches. This modularity offers better overall performance scalability than is feasible with sophisticated power modules. In addition, ZF’s “discrete offer technology” demands fewer types of factors than working with traditional power modules.

  • With a new, hugely built-in e-motor, ZF increases the power density in comparison to the technological innovation now obtainable in the market. A new cooling principle and a new winding engineering enjoy the decisive position in this article. Due to the new cooling principle, ZF enables oil to flow straight all-around the copper rods—exactly at the point where most heat is created throughout procedure. These types of remarkably productive cooling noticeably boosts general performance with the same excess weight and installation house. The ongoing electric power of the electrical motor is amplified to up to 85% of the peak ability.


    E-Motor Stator with new braided winding

    In addition, the use of significant unusual earths can be mainly dispensed with, and the e-motor can as a result be generated much more sustainably. The braided winding technological know-how designed by ZF, a even further development of the hairpin winding, permits a total of 10% considerably less installation area. The winding head by yourself is all around 50% smaller than with regular techniques. This means that all around 10% much less raw substance is processed.

  • With its new coaxial reduction gearbox, ZF transfers its know-how in planetary gearboxes to the following generation of electric powered drives. Two built-in planetary gears not only create the ideal axle ratio, but also consist of the thoroughly built-in differential purpose. As opposed to prevalent offset concepts, the new resolution cuts down excess weight and installation area necessities without compromising efficiency, sounds, and vibration.


    Integrated differential gear

  • Large-voltage converters (DC-DC converters) participate in a central role in gas mobile-run electrical drives. They compensate for the small output voltage and the solid voltage fall at large load of the fuel cells. The new high-voltage converter from the ZF electricity electronics system, which was designed for passenger motor vehicle and professional car or truck purposes, has a prime benefit of 99.6% in terms of performance.


    New large voltage converter

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