Into the Future –
With e-Mobility
ZF PRODUCTS FOR HYBRID
AND ELECTRIC VEHICLES
Contents
2
Electric mobility – a megatrend with potential
page4
Diversity in efficiency:
electrification of the driveline
page6
New features thanks to e-mobility
page8
Electric Motor
page10
Hybrid module
page11
Hybrid Transmission
page12
48V Hybrid system
page13
Power Unit
page14
Electric vehilce drive
page15
ELECTRIC TWIST BEAM AXLE
page16
Modular electric rear axle concept
page17
The ZF Group
page18
Research and development To secure mobility
page19
INNOVATIVE AND FIT FOR THE FUTURE.
Millions of people around the entire world
are driving with car driveline technology
from ZF – today and in the future. The
products are designed for efficiency and
are simultaneously setting standards when
it comes to comfort and driving dynamics.
Vehicles equipped with ZF technology successfully walk the challenging line between
the need to shape individual mobility while
also doing everything possible to preserve
the environment and resources. It is impossible to imagine automobiles of the future
without ZF driveline technology because,
with its modern and reliable components,
ZF is also paving the way for many trends,
such as electrification of the driveline. This
culture of innovation as well as the ability to produce components of the highest
quality has made ZF a valuable partner in
the international automotive industry.
3
Electric mobility –
a megatrend with potential
Electric drives are an important element required to make
sustainable mobility concepts possible. In this context,
ZF provides innovative systems and components.
Already more than 100 years ago, engineers experi-
and combustion-engine drives. Pure electric vehicles are
motors with different power output figures for use in par-
larly efficient. Customers who buy electric drive systems
mented with electric drives for the early automobiles.
already in use without causing any local emissions – and
allel hybrid concepts. The product portfolio ranges from
from ZF benefit from the Group’s overall expertise. After
The fact that, in the end, a drive concept based on liquid
as soon as their batteries are charged with green electric-
integrated 48V solutions with 15 kW which can be used
all, ZF has valuable system know-how about the entire
fuel gained from fossil fuels established itself and is
ity their overall carbon footprint will improve consider-
in mild hybrid systems and already offer a large number
driveline, including its functional and structural inte-
still in use today could soon prove to be only a phase in
ably. Fuel cell vehicles are also purely electrically driven.
of advantages of electric drives to powerful electric mo-
gration into the automobile. The Group’s expertise in
automotive history. The past decades have shown us the
In this case, advantages in terms of range result from the
tors with up to 120 kW for plug-in hybrid transmissions.
the area of mechanics derived from its well-established
limits of fossil fuels: Global oil reserves will not be avail-
required energy generated on the road based on hydro-
Automotive manufacturers appreciate ZF’s expertise in
driveline technology product portfolio is equally valu-
able indefinitely, emissions caused by traffic damage the
gen or methanol stored in tanks.
offering complete hybrid modules in which the electric
able to ZF customers. It includes topics as complex as the
climate and the environment. In this context, the demand
motor, a separating clutch, and torsional dampers which
damping of torsional engine vibrations or efficient torque
for individual mobility which is still increasing fast,
ZF: Solutions from a single source
balance out rotational irregularities of the combustion
transmission.
particularly in emerging industrialized nations or “emerg-
In the context of this electrification megatrend, automo-
engine are integrated in very limited space. ZF uses these
ing markets”, can hardly be fulfilled based on combustion
tive manufacturers can rely on the technology company
hybrid modules in its own systems, for instance in the
engine drive concepts. Legislators are also starting to
ZF. After all, ZF has been developing electric drives for
plug-in hybrid transmission based on the 8-speed auto-
play an increasingly bigger role in this matter: Globally,
vehicles for more than 25 years. In 2008, the company
matic transmission.
the automotive industry has to respect ever stricter fleet
inaugurated the first industrial production facility for
consumption and emission limits. Therefore, alternative
electric motors for hybrid electric vehicles in Europe.
drive concepts for passenger cars are now and will be
For pure electric vehicles ZF supplies weight-saving
electric axle drives which take up little installation space.
in high demand in the future – and for many of them,
Today electric drive components from ZF offer solutions
These include the electric motor, a two-stage spur gear
electricity as a power source plays an important role: Hy-
for almost any passenger car manufacturer concept,
drive, as well as the power electronics system in one
brid electric vehicles combine the advantages of electric
starting with the development and production of electric
package. Its high speed design makes the system particu-
4
5
Diversity in efficiency:
electrification of the driveline
overview of electrified drive configurations
HEV – Hybrid Electric Vehicles
EV – Electric Vehicles
Nowadays, e-mobility covers a very broad range of
drive system types for which ZF is optimally prepared
today and in the future.
Full hybrid, parallel
rear-wheel drive
More cost-effectiveness and less or no emissions: This
serial hybrid drives are integrated according to a differ-
is the objective when it comes to implementing almost
ent model: In most cases, the combustion engine drives a
all electrified passenger car drives. This goal can be
generator which supplies energy for one or more electric
achieved in different ways.
motors for the axle or wheel drive.
Twice as powerful
Simply great
In hybrid electric vehicles or HEV, the conventional
Finally, in pure electric vehicles or EV, no combustion
combustion engine is supported by at least one electric
engine is installed at all. The energy for the electric
motor. Its respective capacity can be used for an initial
motor or motors is either supplied by a battery, as is the
classification: A micro hybrid can, for example, switch off
case for battery electric vehicles or BEV; or a fuel cell on
the combustion engine in a stationary vehicle (start/stop)
board generates the electric energy by means of a chemi-
as well as recuperate braking energy to a limited extent
cal reaction, as is the case for fuel-cell vehicles (fuel cell
but does not actively drive the vehicle. The latter is pos-
(electric) vehicle – FC(E)V). ZF works intensively on elec-
sible starting with the mild hybrid in which an electric
tric vehicle innovations, particularly with its complete
motor for instance complements the gasoline or diesel
electric axle drive systems.
Mild hybrid, parallel
rear-wheel drive
48 V or high voltage
Full hybrid, parallel
front-transverse drive
Battery electric vehicle
Fuel Cell
Full hybrid
front-transverse drive
with electric motor
electric 4-wheel drive
Mild hybrid, parallel
front-transverse drive
48 V or high voltage
Serial hybrid
or range extender
Fuel-cell (electric) vehicle
engine via the boost mode; it can, however, not drive
the car independently. This is possible in the full hybrid
Cost-effective at 48 V
which, as a plug-in hybrid electric vehicle (PHEV), can
A more powerful on-board supply system in passenger
also be charged using any power outlet. It already tackles
cars had already been a topic in the automotive industry
many everyday challenges purely electrically: A PHEV
before hybrid vehicles were introduced: After all, elec-
equipped with the ZF plug-in hybrid transmission even
trics and electronics mean more and more consumers
reaches speeds of up to 120 km/h and a range of up to 50
in the passenger car, taxing the classical 12 V network
kilometers without generating any local emissions.
to the limits of its capacity. An additional 48 V on-board
Overview of hybrid categories
Hybrid categories
Main functions
Micro
Mild 48V
Full (HEV)
Plug-in (PHEV)
Start/stop
(Boost mode)
(Recuperation)
Start/stop
Boost mode
Recuperation
(Electric maneuvering)
Start/stop
Boost mode
Recuperation
Limited electric driving
Sailing
Start/stop
Boost mode
Recuperation
Electric driving
Sailing
3-5 kW
10 -15 kW
20-50 kW
75-120 kW
supply system is also a less costly step toward hybridizaAs an alternative, HEVs can also be categorized based on
tion. A mild hybrid system based on 48 Volts already
the interplay between the conventional combustion en-
makes a large number of hybrid functions possible – sail-
gine and the electric motor: A hybrid in which both can
ing, boost mode, recuperation, electric starting, crawling,
influence the same driveline simultaneously and directly,
as well as start/stop. Thanks to the low-voltage system,
as is the case for the mild hybrid or PHEV, is a parallel
the electronic components can, however, be integrated in
hybrid. And this is exactly the type of hybrid ZF focuses
the vehicle at low cost. This results in fuel savings of 10
on for passenger cars. By contrast, the electric motors in
to 15 percent.
6
Max. performance level
7
New features
thanks to e-mobility
Functions of the hybrid system
Start/stop
The electric drive starts the combustion engine
and stops it comfortably if required.
Recuperation
Braking energy is converted into electric energy.
Boost mode
Hybrid or pure electric drives offer a number of functions
which make driving more efficient.
While starting or accelerating, the torque of the
combustion engine is increased by the additional
torque of the electric motor.
Electric driving / electric maneuvering
Start/stop
Electric driving
Switching off the combustion engine whenever it is not
As soon as electric motors drive the passenger car inde-
required reduces consumption. This is above all the
pendently, no more emissions are caused locally while
case when the vehicle is at a standstill. Today start/stop
driving – and hardly any noise is generated. These are
systems are therefore even integrated in vehicles without
huge advantages, not least in inner city areas where strict
hybrid drive.
access restrictions for vehicles with conventional drives
The electric drive unit drives the vehicle
independently.
are becoming more and more common.
Recuperation
When the vehicle decelerates, the electric motor is used
Electric maneuvering
as a generator to convert the braking energy into electric
Combustion engine vehicles consume a lot of fuel when
energy and to charge the battery.
starting from a standstill or maneuvering at walking
speed. When the electric motor takes over this task, the
Boost mode
Sailing
Switching off and decoupling the combustion engine
while driving, for instance when letting the vehicle coast
to a stop. If required, the engine is switched on again by
a tap on the accelerator pedal.
vehicles use considerably less fuel.
When full power is required in the hybrid vehicle, the
electric motor supports the combustion engine. Advan-
Sailing
tage: For this reason, the latter can already be designed
In driving situations requiring little power input, such as
to be smaller and more fuel-efficient in hybrid vehicles –
when driving at constant speed or slightly downhill, the
keyword: downsizing.
combustion engine is switched off and the electric motor
takes over vehicle propulsion if required.
8
9
ELECTRIC MOTOR
HYBRID MODULE
PRODUCT DETAILS ELECTRIC DRIVES
PRODUCT DETAILS ELECTRIC DRIVES
Specification
Permanent-field synchronous machine (PSM)
Type
Outer diameter
Unit
Drive configuration
Specification
Type
AL280-32
280
mm
Outer diameter
32
mm
Active length
approx. 150
mm
Axial length module
220 – 420
Vdc
Voltage range
Max. power
55
kW
Max. torque
250
Nm
Max. speed
7,000
rpm
Active length
Axial length module
Voltage range
Permanent-field synchronous machine (PSM)
Mild hybrid, parallel
front-transverse drive
48 V or high voltage
Full hybrid, parallel
front-transverse drive
Unit
AL280-80
280
mm
80
mm
approx. 240
mm
220 – 420
Vdc
Max. power
90
kW
Max. torque
400
Nm
Max. speed
7,000
rpm
800
Nm
Max. torque separarting clutch
Consisting of
Consisting of
Electric motor
Torsional vibration damper
Rotor position sensor
Housing
Electric motor
Torsional vibration damper
Separating clutch
Separating clutch actuation
Housing
Drive configuration
Full hybrid, parallel
front-transverse drive
Full hybrid, parallel
rear-wheel drive
Electric motor
Rotor position sensor
Separating clutch
Electric motor
Interface to transmission
Torsional vibration damper
Torsional vibration damper
Interface to transmission
Interface to combustion engine
Interface to combustion engine
Housing
Housing
Separating clutch
actuation
10
11
HYBRID TRANSMISSION
48V HYBRID SYSTEM
PRODUCT DETAILS ELECTRIC DRIVES
PRODUCT DETAILS ELECTRIC DRIVES
Specification
Permanent-field synchronous machine (PSM)
Type
Outer diameter
Unit
Drive configuration
Specification
Type
IL269-70
269
mm
Outer diameter
70
mm
Active length
approx. 150
mm
Axial length module
220 – 420
Vdc
Voltage range
Max. power
90
kW
Max. torque
250
Nm
Max. speed
7,000
rpm
Active length
Axial length module
Voltage range
Permanent-field synchronous machine (PSM)
Full hybrid, parallel
rear-wheel drive
mm
51
mm
approx. 145
mm
36 – 52
Vdc
Max. power
15
kW
Max. torque
200
Nm
Max. speed
7,000
rpm
800
Nm
Consisting of
Consisting of
Electric motor
Torsional vibration damper
Separating clutch
Housing
Electric motor
Power unit incl. rotor position sensor
Housing
Optional: torsional vibration damper
Optional: separating element
Drive configuration
IL292-51
292
Max. torque separating element (optional)
Separating clutch
Unit
Mild hybrid, parallel
front-transverse drive
48 V or high voltage
Mild hybrid, parallel
rear-wheel drive
48 V or high voltage
Interface to transmission
Housing
Interface to optional
torsional vibration damper
Interface to
combustion engine
Electric motor
Torsional vibration damper
Electric motor
12
Power unit incl. rotor position sensor
Housing
13
POWER UNIT
ELECTRIC VEHICLE DRIVE
PRODUCT DETAILS
PRODUCT DETAILS ELECTRIC DRIVES
Specification
Type
Volume
Power unit
Unit
Drive configuration
Specification
Type
PUM
Dimensions incl. housing
8
l
Max. voltage
440
Vdc
Max. current
510
Arms
Axial length module
Continuous current
240
Arms
Voltage range
C
ASIL
Active length
Asynchronous machine (ASM)
Unit
Drive configuration
eVD2
450 x 510 x 380
mm
150
mm
approx. 450
mm
220 – 420
Vdc
150
kW
3,500
Nm
13,000
rpm
Fuel Cell
Safety level
Max. power
Fuel Cell
Max. speed
7,000
rpm
Max. torque at axle
Max. speed
Full hybrid
front-transverse drive
with electric motor
electric 4-wheel drive
Battery electric vehicle
Fuel-cell (electric) vehicle
Consisting of
Electric motor
Two-stage spur gear drive
Power unit
Parking lock
Differential
Housing
Power unit
Electric motor
Parking lock
Two-stage spur gear drive
Housing
Differential
14
15
ELECTRIC TWIST BEAM AXLE
Modular electric
rear axle concept
PRODUCT DETAILS ELECTRIC DRIVES
An electric drive system integrated into the axle
PRODUCT DETAILS
According to the customers, supplying driveline and
Specification
Permanent-field synchronous machine (PSM)
Type
Dimensions incl. damper
and top mount
Active length
Voltage range
Max. power
Max. torque at axle
Max. speed
Unit
chassis technology from a single source has always been
Drive configuration
ZF‘s strength. This advantage also remains in times
eTB
approx. 595 x 1500 x 250 (560)
Drive configuration
of e-mobility. For instance, ZF offers the electric drive
integrated into a complete axle system. For ZF customers,
mm
this considerably reduces development costs because
90
ZF handles the coordination of internal interfaces.
mm
220 – 420
Vdc
75
kW
1,400
Nm
21,000
rpm
Fuel Cell
Fuel Cell
ZF develops, fine-tunes, and tests the axle including
the electric drive, in accordance with the requirement
specification. In the process, different axle types can be
Full hybrid
front-transverse drive
with electric motor
electric 4-wheel drive
Battery electric vehicle
Fuel-cell (electric) vehicle
used depending on the application. For this purpose, ZF
provides a modular rear axle concept which is based on
essential customer requirements. Since ZF can imple-
Full hybrid
front-transverse drive
with electric motor
electric 4-wheel drive
Battery electric vehicle
Fuel-cell (electric) vehicle
ment its experience with passenger car axle systems in
the process, the electric drive is integrated seamlessly
Consisting of
Electric motor
Two-stage spur gear drive
Aluminum housing
Integrated mounting
of damper & spring
Twist-beam axle
16
and according to the requirements.
17
The ZF Group
Research and development to
secure mobility
Innovations are not an end in themselves, they must pay off: For manufacturers, fleet owners, and drivers, but also for the environment and society. Each
new development must prove itself among the conflicting priorities of these
criteria.
Shaping the future responsibly
Our enthusiasm for innovative products and processes and our uncompromising pursuit of quality have made
us a global leader in driveline and chassis as well as active and passive safety technology. We are contributing
towards a sustainable future by producing advanced technology solutions with the goal of improving mobility,
increasing the efficiency of our products and systems, and conserving resources.
Our customers in the automotive and industrial sectors welcome our systematic orientation towards products
and services which provide great customer value. Improvements in energy efficiency, cost-effectiveness, dynamics, safety, and comfort are key to our work. Simultaneously, we are aiming for continuous improvement in our
business processes and the services we provide.As a globally active company, we react quickly and flexibly to
changing regional market demands with the goal of always providing a competitive price/performance ratio.
The ZF Group draws upon an international network of
What‘s more, the innovative power of ZF is set to
development centers. Each year, ZF invests approxi-
increase in the future. Proof of this is already provided
mately five percent of its sales in R&D. With success,
by the number of patents pending: A look at the statistics
because innovative products from ZF set the standards
of the German Patent and Trademark Register shows that
for state-of-the-art technology – again and again.
ZF is among the top ten applicants for patents – at eye
level with many large automotive manufacturers. Each
Development work at ZF is organized according to
year, the research departments successfully complete
decentralized and corporate functions. The divisions
more than 10 000 projects, covering the full range from
and business units focus on markets and product exper-
basic research to product applications. This high project
tise, ensuring customer-centered, competitive techno-
volume is necessary to ensure mobility in the future. The
logical product development. Corporate R&D works
trend toward hybrid solutions already shows that green
Our independence and financial security form the basis of our long-term business success. Our profitability
enables us to make the necessary investments in new products, technologies, and markets and we thus secure
the future of our company on behalf of our customers, market affiliates, employees, and ZF owners.
with a strong emphasis on basic research and theory,
drive technology is very complex. The same goes for pure
and supports the operational development departments
electric drives and lightweight design engineering. Cur-
in the divisions.
rently, ZF engineers are conducting pioneering work on
Our tradition and values strengthen our managerial decisions. Together, they are both an obligation and an
incentive to maintain a reliable and respectful relationship with customers, market affiliates, and employees.
Our worldwide compliance organization ensures that locally applicable laws and regulations are adhered to.
We accept our responsibility towards society and will protect the environment at all of our locations.
Groundbreaking innovations
alternative materials, broader approaches in design and
testing, and new production processes.
Over the past years, this partnership has produced
product innovations that have since become benchmarks in the industry: Just some examples are the
8-speed automatic transmission for cars as well as
Our employees worldwide recognize us as a fair employer, focusing on the future and offering attractive career
prospects. We value the varied cultural backgrounds of our employees, their competencies, and their diligence
and motivation. Their goal-oriented dedication to ZF, beyond the borders of their own field of work and location,
shapes our company culture and is the key to our success.
hybrid transmissions and hybrid management for
cars and commercial vehicles, or the modular TraXon
transmission system for commercial vehicles. Groundbreaking innovations from ZF are in use today not just
in passenger cars and commercial vehicles on the road,
but also in all kinds of craft on the water and in the air.
18
19
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© ZF Friedrichshafen AG - E-Mobility Cars Electric Drive Technology - 09/2015 (EN20150831)
ZF Friedrichshafen AG
Ernst-Sachs-Strasse 62
D-97424 Schweinfurt
Germany
Phone +49 9721 98-0
Fax
+49 9721 98-2290
www.zf.com