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Country Profile Czech Republic

Research & Developement in Plzeň

We make things possible

The Czech subsidiary of the Corporate Research and Development of ZF Friedrichshafen AG offers Comprehensive mechatronic solution. As ZF is leading with the integration of electronic control system intro Driveline and Chassis Technology, you can rely on ZF Engineering Plzen as a high-performance center of competence. Our scope of engineering services ranges from design to prototyping, from environmental tests up to the realization of customer-specific test facilities.

Products

ZF Engineering Plzeň creates automatic test systems for electronics, hydraulics, pneumatics and mechatronic devices. Solutions driven by your demands of quality:

Test Systems and Special-Purpose Machines

Test Systems and Special-Purpose Machines

Ideas become Reality

ZF Engineering Plzeň develops designs and creates measuring and testing technology as well as special-purpose machines for individual applications. Our knowledge and experience in mechatronics, design and mechanical engineering is available in Pilsen and forms the basis for finding a flexible, interdisciplinary solution which concentrates on customer requirements.

Individual test systems, special-purpose machines and apparatus construction

ZF Engineering Plzeň creates automatic test systems for electronics, hydraulics, pneumatics and mechatronic devices. We design, develop and realize endurance test benches for product validation purposes as well as for functional End-of-line testers.

We are pleased to support you in the evaluation of test programs according to automotive standards. Due to our special knowledge in automotive applications, we provide test performance and reporting from one source.

Special-purpose machines

Product development

Customizing

Functional test benches

EOL-Testers

Quality assurance

According to your demands we design fixtures that perform your assembly processes. Depending on the assembly principle and the cycle time demanded, we create fully automatic, semiautomatic or manual assembly fixtures. Thereby, we consider ease of use and ergonomic design as focal points.

Customized special-purpose machines to support your series- or prototype production processes. Solution driven by your demands on quality.

Assembly devices

Manual

Half automatic

Full automatic

Special- purpose machinery

Assembly lines

Production machines

Analysis of Components and Environmental Testing

Analysis of components and environmental testing

Environmental tests according to the automotive standards

  • Validation of development samples
  • Test of mechatronic systems and components
  • Climatic and temperature tests
  • Thermal shock tests
  • Durability tests

Optical inspection and analysis

  • Microscopic
  • Macroscopic
  • Boroscopic
  • Examinations and measurements

Inspection of electronic contacts

  • Force and strain tests
  • 3D-measurements on CMM

Hydraulic components and systems

  • Qualification
  • Functional tests and analysis
Environmental tests Tests of hydraulic components Measurements and tests
Climatic chamber 6500 l Warm and cold pressure oil Force and strain test

  • Temperature range: -40°C to +150°C
  • Humidity range: 10% r.h. to 98% r.h.
  • Test space: 1900 x 2000 x 1700 mm
  • Temperature gradient: 1K to 3K/min

  • Pressure (max): 80 bar
  • Temperature range: -25°C to +150°C
  • Flow rate (max): 0,7 l/s
  • Test space: 1000 x 500 x 500 mm

  • Force and strain test: 500N to 5kN
  • Process speed: up to 50 mm/s
  • Software: TestXpert v 12.1
Climatic chamber 600 l Warm pressure oil 3D-Measurement
  • Temperature range: -40°C to +180°C
  • Humidity range: 10% r.h. to 98% r.h.
  • Test space: 800 x 800 x 950 mm
  • Temperature gradient: 1K to 3K/min

  • Pressure (max): 30 bar
  • Temperature range: RT to +130°C
  • Flow rate (max): 0,9 l/s
  • Test space: 1000 x 500 x 500 mm

  • Sample size (max): 1500 x 700 x 600 mm
  • Software: LK Camio Studio
Climatic chamber 300 l Microscopic and macroscopic inspection
  • Warm chamber: +50°C to +220°C
  • Cold chamber: -75°C to +70°C
  • Test space: 770 x 650 x 610 mm
  • Weight of sample (max): 50 kg
  • Transfer time: < 5s

  • Zoom (max): 500-fach
  • Camera system: 5 Mpx
Oven 180 l

  • Temperature range: RT to +300°C
  • Test space: 554 x 644 x 503 mm
  • Temperature gradient: 4K/min

Automation

Automation

Measurement, Control, Visualization

We realize customer specific automation systems based on PLC- and PC-controls.

Graphical user Interfaces (GUI) and the visualization of test procedures for intuitional user guidance.

We are providing comprehensive support from first specification to the final delivery. Our goal is to meet your needs and to ensure the highest quality.

We produce single devices as well as small-scale series with the highest cost efficiency.

PLC-Programming

  • Feedforward and closed loop controls
  • Automated procedures and sequences

PC based Controls

  • LabVIEW applications
  • Data aquisition and postprocessing
  • Graphical user interface (GUI)

Switchboards

  • Layout
  • Assembly
  • Small-scale production

Prototyping

Prototyping

Conceptions to Grab - Ideas to Touch

ZF Engineering Plzeň offers cost- efficient capabilities to make your ideas become reality at the earliest time of the conception- and development process. We apply technology which facilitates a wide ranging variety of applications at low cost - starting with the first display model up to the functional component, from quantity 1 up to small scale production.

Rapid prototyping, rapid tooling, injection moulds

Ideas to touch

  • Colored 3-D print to illustrate FEM results
  • Design models for customer presentations

Integration and installation tests under control

  • Early consideration of installation space and neighborhood relationships
  • Realistic assembly simulations in parallel to design cycles

Transparent models provide perspective

  • Checking of lubricants flow

Realisation of functional prototypes

  • Mechanical parts for functional tests
  • Mechatronic prototypes Integration of sensor assemblies and interconnection devices

Best cost small scale production

  • Small-scale production of plastic parts from 10 up to 2500 pieces
  • Material and tool alternatives for your decision processes
  • Electronic and mechatronic prototypes from 1 to 100 pieces

Products

Products

Products survey of ZF Engineering Plzeň

ZF Engineering Plzeň creates automatic test systems for electronics, hydraulics, pneumatics and mechatronic devices. We design, develop and realize endurance test benches for product validation purposes as well as for functional end-of-line testers.

We are pleased to support you in the evaluation of test programs according to automotive standards. Due to our special knowledge in automotive applications, we provide test performance and reporting from one source.

According to your demands we design fixtures that perform your assembly processes. Depending on the assembly principle and the cycle time demanded, we create fully automatic, semiautomatic or manual assembly fixtures. Thereby, we consider ease of use and ergonomic design as focal points.

Customized special-purpose machines to support your series- or prototype production processes. Solution driven by your demands on quality.

Prototyping

Rapid Prototyping

RP for vehicle testing

RP for putting in operation on an assembly line

RP for oil leak testing

Test Device

Mechatronic - test device

Oil displacer

Control system for oil displacer

6HP / 8HP-Modultester

Test device for pressure sensor testing

Switch tester

Tooling

Tool and mould manufacturing

PUR-tool with 10 cavities

Injection mould

Tools for light-weight products

Tools for light-weight products

Preparation

Preparation and assembly application

Mounting device

Folding machine

Mounting device

About ZF Engineering Plzeň

About ZF Engineering Plzeň

Development and test services for internal and external customers

ZF Engineering Plzeň offers development and test services to ZF Group and to external customers.

One of the 8 main development sites of the ZF Group

ZF Engineering Plzeň was integrated to the ZF Group in July 2007 by taking over an existing independent development centre. Since this time the branch has been continuously built-up. During first 3 years the number of employees has been increased from 50 to ca. 150.

At the present time ZF Engineering Plzeň is one of the 8 main development sites of the ZF Group. In defined competence field the development and test services are offered to ZF Group and to external customers.

In mechatronics area the complete development chain from design via prototyping to testing is available. Automated test and assembly devices can be realized in house and complete the whole spectrum.

Quality

Quality

Certification and quality management in ZF Engineering Plzeň.

Scope of quality

  • Establishment, documentation, maintenance and continuous improvement of quality management system according to requirement of standard ČSN EN ISO 9001:2008.
  • Verification of functionality, efficiency and suitability of established quality management system.
  • Planning, organization and control of internal audits.
  • Identification and initiation of measures leading to increasement of quality of processes, products and services.

Certificates

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Locations and addresses

Find all addresses of ZF locations in Czech Republic