Into the Future – with E-Mobility - zf.com · valuable partner in the international automotive...

Into the Future – with E-MobilityZF products for hybrid and electric vehicles

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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.

01Electric Mobility 04 Electric Mobility – A Megatrend with Potential

02Drive Systems 06 Diversity in Efficiency: Electrification of the Driveline 08 New Features thanks to E-Mobility

03Products 09 48V Hybrid System 10 Electric Motor 11 Hybrid Module 12 Hybrid Transmission 13 Power Unit 14 Electric Vehicle Drive 15 Modular Electric Rear Axle Concept

E-Mobility Cars Electric Drive Technology Content

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Automotive manufacturers appreciate ZF’s expertise in offering complete hybrid modules in which the electric motor, a separating clutch, and torsional dampers which balance out rotational irregularities of the combustion engine are integrated in very limited space. ZF uses these hybrid modules in its own systems, for instance in the plug-in hybrid transmission based on the 8-speed automatic transmission. For pure electric vehicles ZF supplies weight-saving electric axle drives which take up little installation space. These include the electric motor, a two-stage spur gear drive, as well as the power electronics system in one package. Its high speed design makes the system particularly efficient. Customers who buy electric drive systems from ZF benefit from the Group’s overall exper-tise. After all, ZF has valuable system know-how about the entire driveline, including its functional and structural integration into the automobile. The Group’s expertise in the area of mechanics derived from its well-established driveline technology product portfolio is equally valuable to ZF customers. It includes topics as complex as the damping of torsional engine vibrations or efficient torque transmission.

Already more than 100 years ago, engineers experimen-ted with electric drives for the early automobiles. The fact that, in the end, a drive concept based on liquid fuel gained from fossil fuels established itself and is still in use today could soon prove to be only a phase in automotive history. The past decades have shown us the limits of fossil fuels: Global oil reserves will not be available indefinitely, emissions caused by traffic dama-ge the climate and the environment. In this context, the demand for individual mobility which is still increasing fast, particularly in emerging industrialized nations or “emerging markets”, can hardly be fulfilled based on combustion engine drive concepts. Legislators are also starting to play an increasingly bigger role in this matter: Globally, the automotive industry has to respect ever stricter fleet consumption and emission limits. Therefore, alternative drive concepts for passenger cars are now and will be in high demand in the future – and for many of them, electricity as a power source plays an important role: Hybrid electric vehicles combine the advantages of electric and combustion-engine drives. Pure electric vehicles are already in use without causing any local emissions – and as soon as their batteries

are charged with green electricity their overall carbon footprint will improve considerably. Fuel cell vehicles are also purely electrically driven. In this case, advantages in terms of range result from the required energy generated on the road based on hydrogen or methanol stored in tanks. ZF: Solutions from a single source In the context of this electrification megatrend, automo-tive manufacturers can rely on the technology company ZF. After all, ZF has been developing electric drives for vehicles for more than 25 years. In 2008, the company inaugurated the first industrial production facility for electric motors for hybrid electric vehicles in Europe. Today electric drive components from ZF offer solutions for almost any passenger car manufacturer concept, starting with the development and production of electric motors with different power output figures for use in pa-rallel hybrid concepts. The product portfolio ranges from integrated 48V solutions with 15 kW which can be used in mild hybrid systems and already offer a large number of advantages of electric drives to powerful electric mo-tors with up to 160 kW for plug-in hybrid transmissions.

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.

E-Mobility Cars Electric Drive Technology Electric Mobility

Fuel Cell

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More cost-effectiveness and less or no emissions: This is the objective when it comes to implementing almost all electrified passenger car drives. This goal can be achie-ved in different ways. In hybrid electric vehicles or HEV, the conventional combustion engine is supported by at least one electric motor. Its respective capacity can be used for an initial classification: A micro hybrid can, for example, switch off the combustion engine in a stationary vehicle (start/stop) as well as recuperate braking energy to a limited extent but does not actively drive the vehicle. The latter is possible starting with the mild hybrid in which an electric motor for instance complements the gasoline or diesel engine via the boost mode; it can, however, not drive the car independently. This is possible in the full hybrid which, as a plug-in hybrid electric vehicle (PHEV), can also be charged using any power outlet. It already tackles many everyday challenges purely electrically: A PHEV equipped with the ZF plug-in hybrid transmission even reaches speeds of up to 120 km/h and a range of up to 50 kilometers without generating any local emissions. As an alternative, HEVs can also be categorized based on the interplay between the conventional combustion engine and the electric motor: A hybrid in which both can influence the same driveline simultaneously and directly, as is the case for the mild hybrid or PHEV, is a parallel hybrid. And this is exactly the type of hybrid ZF focuses on for passenger cars. By contrast, the electric motors in serial hybrid drives are integrated according to

a different model: In most cases, the combustion engine drives a generator which supplies energy for one or more electric motors for the axle or wheel drive. Finally, in pure electric vehicles or EV, no combustion engine is installed at all. The energy for the electric motor or motors is either supplied by a battery, as is the case for battery electric vehicles or BEV; or a fuel cell on board generates the electric energy by means of a che-mical reaction, as is the case for fuel-cell vehicles (fuel cell (electric) vehicle – FC(E)V). ZF works intensively on electric vehicle innovations, particularly with its complete electric axle drive systems. A more powerful on-board supply system in passenger cars had already been a topic in the automotive industry before hybrid vehicles were introduced: After all, elec-trics and electronics mean more and more consumers in the passenger car, taxing the classical 12V network to the limits of its capacity. An additional 48V on-board supply system is also a less costly step toward hybridiza-tion. A mild hybrid system based on 48 Volts already ma-kes a large number of hybrid functions possible – sailing, boost mode, recuperation, electric starting, crawling, as well as start/stop. Thanks to the low-voltage system, the electronic components can, however, be integrated in the vehicle at low cost. This results in fuel savings of 10 to 15 percent.

Diversity in Efficiency – Electrification of the Driveline

Overview of Electrified Drive Configurations

Overview of Hybrid Categories

HEV – Hybrid Electric Vehicles

Full hybrid, parallel rear-wheel drive

Full hybrid front-transverse drive with electric motor

electric 4-wheel drive

Mild hybrid, parallel rear-wheel drive

48V or high voltage

Mild hybrid, parallel front-transverse drive 48V or high voltage

Full hybrid, parallel front-transverse drive

Serial hybrid or range extender

Battery electric vehicle

Fuel-cell (electric) vehicle

Hybrid categories Micro Mild 48V Full (HEV) Plug-in (PHEV)

Main functions Start/stop (Boost mode)

(Recuperation)

Start/stop Boost mode

Recuperation (Electric maneuvering)


Recuperation Limited electric driving

Sailing


Recuperation Electric driving

Sailing

Type performance level 3-10 kW 15-25 kW 40-75 kW 75-160 kW

E-Mobility Cars Electric Drive Technology Drive Systems

EV – Electric Vehicles

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Hybrid or pure electric drives offer a number of functions which make driving more efficient.

Start/stop Switching off the combustion engine whenever it is not required reduces consumption. This is above all the case when the vehicle is at a standstill. Today start/stop systems are therefore even integrated in vehicles without hybrid drive. Recuperation When the vehicle decelerates, the electric motor is used as a generator to convert the braking energy into electric energy and to charge the battery. Boost mode When full power is required in the hybrid vehicle, the electric motor supports the combustion engine. Advan-tage: For this reason, the latter can already be designed to be smaller and more fuel-efficient in hybrid vehicles – keyword: downsizing. Electric driving As soon as electric motors drive the passenger car independently, no more emissions are caused locally while driving – and hardly any noise is generated. These are huge advantages, not least in inner city areas where strict access restrictions for vehicles with conventional drives are becoming more and more common. Sailing In driving situations requiring little power input, such as when driving at constant speed or slightly downhill, the combustion engine is switched off and the electric motor takes over vehicle propulsion if required.

New Features thanks to E-Mobility

48V Hybrid System

Consisting of 48V Electric motor Highly integrated 48V inverter incl. rotor position sensor Housing Dog clutch (optional) Electro-magnetic release system (optional)

Specification Permanent-field synchronous machine (PSM) Unit Drive configuration

Type PI286F10U1L50

Outer diameter 286 mm

Active length 50 mm

Voltage range 36 – 52 Vdc

Max. power mot. (10s) 20 kW

Max. power gen. (10s) 24 kW

Max. power mot. cont. 14 kW

Max. power gen. cont. 17 kW

Max. torque cold @ 0°C @ 900A 205 Nm

Max. torque warm @ 120°C @ 800A 180 Nm

Interface to optional torsional vibration damper

Power unit incl. rotor position sensor

Interface to transmission

Housing

Electric motor


Mild hybrid, parallel rear-wheel drive

48V or high voltage

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Type AL280-32


Active length 32 mm

Axial length module approx. 150 mm


Max. power 55 kW

Max. torque 250 Nm

Max. speed 7,000 rpm

Electric Motor


Interface to combustion engine

Torsional vibration damper

Housing

Electric motor

Rotor position sensor

Consisting of Electric motor Torsional vibration damper Rotor position sensor Housing



Hybrid Module



Housing

Electric motor

Separating clutchactuation

Separating clutch

Consisting of Electric motor Torsional vibration damper Separating clutch Separating clutch actuation Housing


Type AL280-80


Active length 80 mm



Max. power 90 kW

Max. torque 400 Nm

Max. speed 7,000 rpm

Max. torque separarting clutch 800 Nm


Full hybrid, parallel rear-wheel drive


E-Mobility Cars Electric Drive Technology Products

Fuel Cell

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Consisting of Electric motor Torsional vibration damper Separating clutch Housing


Type IL269-70


Active length 70 mm



Max. power 90 kW

Max. torque 250 Nm

Max. speed 7,000 rpmFull hybrid, parallel

rear-wheel drive

Electric motor

Separating clutch

Housing



Hybrid TransmissionProduct details electric drives

Power Unit

Consisting of Inverter

Cooling water connection

Signal connector

Cooling water connection

Housing

High voltage battery connector

Specification Power unit Unit Drive configuration

Type LE Gen4

Volume 5 l

Max. voltage 450 Vdc

Max. current 560 Arms

Continuous current 300 Arms

Safety level D ASIL


Fuel Cell

Fuel Cell

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P2 configuration, parallel front-

transverse drive including separation

clutch C0 for Full-Hybrids and Plug-In Hybrids

Fuel-cell (electric) vehicle

Electric Vehicle Drive

Specification Asynchronous machine (ASM) Unit Drive configuration

Type eVD2

Dimensions incl. housing 450 x 510 x 380 mm

Active length 150 mm



Max. power 150 kW

Max. torque at axle 3,500 Nm

Max. speed 13,000 rpmP1 configuration,

parallel front- transverse drive

Housing Two-stage spur gear drive

Power unit

Electric motor

Parking lock

Differential

Consisting ofElectric motor Two-stage spur gear drive Power unit Parking lock Differential Housing

Drive configuration

Full hybrid front-transverse drive with electric motor

electric 4-wheel drive

Battery electric vehicle Fuel-cell (electric)

vehicle

An electric drive system integrated into the axle According to the customers, supplying driveline and chassis technology from a single source has always been ZF‘s strength. This advantage also remains in times of e-mobility. For instance, ZF offers the electric drive inte-grated into a complete axle system. For ZF customers, this considerably reduces development costs because ZF handles the coordination of internal interfaces. 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 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-ment its experience with passenger car axle systems in the process, the electric drive is integrated seamlessly and according to the requirements.

Modular Electric Rear Axle Concept


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ZF Friedrichshafen AG Ernst-Sachs-Straße 62 D-97424 Schweinfurt Germany T. +49 9721 98-0 F. +49 9721 98-2290 www.zf.com

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Into the Future – with E-Mobility - zf.com · valuable partner in the international automotive...

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