![ZF Unveils Compact, Excessive Torque Drive System For Electrical Vehicles ZF Unveils Compact, Excessive Torque Drive System For Electrical Vehicles](https://bestnology.com/wp-content/uploads/https://cleantechnica.com/files/2023/07/ZF-EVBeat.jpg)
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Behind the flamboyant nameplates on the automobiles we purchase — Mercedes, BMW, Audi, and extra — is a whole business that provides the elements and parts that make these automobiles what they’re. From seats and radios to touchscreens, windshields, and tires, suppliers convey the parts wanted to fabricate cars on to the loading docks of auto factories all over the world. One of the best of them are recognized collectively as Tier One suppliers, and inside that group, Germany’s ZF is among the better of one of the best, together with different outstanding firms corresponding to Bosch, Magna Worldwide, and Siemens.
ZF has 165,000 workers worldwide and operates 168 manufacturing places in 32 nations. In fiscal yr 2022, ZF reported gross sales of €43.8 billion. On its homepage, it describes itself as a world know-how firm supplying techniques for passenger automobiles, business automobiles, and industrial know-how, enabling the subsequent era of mobility.
ZF permits automobiles to see, suppose, and act. Within the 4 know-how domains of Car Movement Management, Built-in Security, Automated Driving, and Electrical Mobility, ZF provides complete product and software program options for established automobile producers. The corporate is utilizing a Porsche Taycan it calls EVbeat as a check mattress for a collection of latest merchandise for electrical automobiles.
With regard to advancing the reason for electrical mobility, ZR introduced on June 29 a brand new built-in drive unit for electrical automobiles that weighs much less and has larger torque than any of its rivals. “Sustainable mobility is on the core of our company technique,” defined Stephan von Schuckmann, a member of the ZF Board of Administration accountable for electrified driveline techniques. “Based mostly on an especially environment friendly manufacturing automobile, we’re displaying the potential that future electrical drive parts supply after we mix them into an much more environment friendly total system.”
The corporate says its EVSys800 is a modular 800 volt drive unit that comes with silicon carbide energy electronics with the electrical motor and a discount gearbox. In comparison with its present 800 volt drive unit, the EVSys800 is 40 kilograms (88 lb) lighter, which may result’s a considerably lighter powertrain. Much less weight below the hood means extra capability for individuals and issues inside.
The unit has a steady energy ranking of 206 kW with a peak of 275 kW. Most torque is alleged to be 70 Newton-meters per kilogram of weight. At 74 kilograms, which means the EVSys800 has over 5000 Newton-meters of torque out there on the drive axle. The brand new bundle is 50 mm narrower than the present unit, because of a extra compact discount gearbox and the ZF-patented “Braided Winding” know-how used to make the electrical motor.
Such a excessive energy drive unit is able to producing plenty of warmth throughout full energy operation. To deal with that, ZF directs cooling oil to stream straight across the copper rods contained in the motor, which is the place a lot of the warmth is generated. The extremely environment friendly cooling system considerably will increase efficiency with out growing the dimensions or weight of the drive unit.
The brand new unit additionally eliminates the necessity for uncommon earth supplies so the electrical motor may be manufactured in a extra sustainable method. The “Braided Winding” know-how developed and patented by ZF is an additional improvement of so-called wave winding, and permits a ten% discount within the area wanted contained in the motor housing. It additionally reduces the quantity of copper required by about 10%. The inverter of the electrical drive has been fully redesigned, as have all different important parts.
A brand new coaxial discount gearbox transmits the drive forces of the electrical motor by way of two planetary gear units. They not solely generate the specified ultimate drive ratio, but in addition carry out the absolutely built-in differential operate. In contrast with standard offset ideas, by which the enter and output shafts are usually not on the identical axis, the coaxial answer reduces weight and set up area necessities with out compromising on effectivity, noise, and vibration. Together with Braided Winding know-how, this drive may be made considerably shorter, permitting set up in virtually any automobile’s set up area.
“Our purpose was to make this drive as compact and light-weight as doable whereas sustaining excessive driving dynamics and growing effectivity in actual world operation,” stated Dr. Otmar Scharrer, Head of Growth for Electrical Driveline Methods at ZF. “By way of torque density, we’re on the prime of the rostrum after we evaluate ourselves with e-drives for passenger automobiles at the moment out there in the marketplace. On the similar time, we paid sturdy consideration to the sustainability facet throughout improvement. With this method, we will completely meet the principle necessities of our prospects — particularly effectivity, efficiency and prices.” The primary manufacturing models of the brand new ZF driveline will probably be out there starting in 2026.
Revised Heating & Cooling System
Heating and cooling can drain a whole lot of energy from the batteries of electrical automobiles. Not solely does the passenger compartment want to remain at a snug temperature, the battery pack should even be cooled throughout excessive energy charging, or heated in chilly climate.
Along with its new EVSys800 energy unit, ZF has additionally developed a digitally managed built-in heating and cooling system referred to as TherMaS that’s mild weight and compact sufficient to suit into most of at the moment’s automobiles. The guts of the system is an 800 volt warmth pump that makes use of propane because the refrigerant.
It might sound counterintuitive to make use of a fossil gas in an electrical automobile, however propane warmth pumps are among the many best out there at the moment. Effectivity is the primary precedence for electrical automobiles with a purpose to journey lengthy distances with out recharging. ZF says the TherMaS system can enhance the vary of an electrical automobile by as a lot as a 3rd throughout chilly climate operation.
The TherMaS idea has three designated circuits. On the middle is the very small refrigerant circuit that’s pre-filled and hermetically sealed to make it maintenance-free. As well as, the idea has no interfaces to different automobile areas, corresponding to the inside. ZF makes use of the fluorine-free pure refrigerant propane. The brand new system makes use of solely half as a lot refrigerant as a standard warmth pump, but delivers twice as a lot cooling energy. The system is designed to satisfy each the comparatively excessive temperatures of the electrical motor and regulate the temperature of the facility and charging electronics. The management software program regulates the cooling capability.
Digital Management Methods & The Cloud
ZF has developed its personal powertrain software program that networks all automobile techniques with one another and establishes the connection to the ZF cloud. The corporate says its new software program bundle can anticipate the optimum working temperatures for any electrical automobile primarily based upon the driving profiles or particular person drivers, and put together the system accordingly. For instance, air con and system cooling are diminished when brief distances are detected.
The digital help system may also give drivers direct recommendation on how one can use the electrical automobile effectively. For instance, environment friendly acceleration and deceleration in addition to an optimized most velocity are displayed, which is especially precious relating to calculating an correct and sensible vary earlier than a journey begins.
The Takeaway
ZF doesn’t construct automobiles, it makes the parts that permit automakers to supply higher automobiles — and tenting trailers. In the present day, many firms favor to convey their provide chains in home. Tesla, for instance, doesn’t purchase seats from a provider. It makes them itself to its personal specs. And but, an outdoor provider like ZF could possibly use economies of scale to make parts out there for much less price than a producer can obtain by constructing them itself.
It’s a fragile dance, however ZF has risen to the extent of a prime tier provider by delivering high quality merchandise on time and on funds. If it may possibly construct a greater drive unit, cooling system, or cloud-based bundle, its fame will guarantee it all the time has loads of prospects. And never each firm needs to go the vertical integration route. Analysis and improvement is pricey, and if a trusted accomplice is prepared to do the heavy lifting, the producer might get a superior product at a relative cut price.
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