ELECTRIC DRIVE SOLUTIONS FOR PASSENGER CARS

Drive electrification is a significant lever with which ZF can contribute toward reducing CO₂ emissions in road traffic. In 2008, the technology company inaugurated the first industrial production facility for electric motors for hybrid electric vehicles in Europe. Nowadays, the electric drive components made by ZF offer solutions for almost all vehicle concepts.

CONSTRUCTION KITS FOR HYBRID DRIVES

It starts with the development and production of electric machines with various power outputs for use in parallel hybrid concepts. The product portfolio ranges from integrated 48 V solutions with 15 kW, which can be used in mild hybrid systems and already offer numerous advantages of electric drives, to powerful electric motors with up to 120 kW for plug-in-hybrid transmissions. Automotive manufacturers appreciate ZF's expertise in offering complete hybrid modules where 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.

PURELY ELECTRIC DRIVES

For purely electric vehicles, ZF supplies weight-saving and compact electric axle drives. These include the electric motor, a two-stage spur gear drive and the power electronics system in one package. The high speed design makes the system particularly efficient.

Customers who buy electric drive systems from ZF benefit from the Group's overall expertise. After all, ZF has valuable system know-how about the entire driveline, including its functional and structural integration in 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.

ZF PRODUCTS FOR E-MOBILITY IN VEHICLES

HYBRID DRIVES

Hybrid module

The turnkey solution for hybrid drives takes up very little installation space. The module integrates the electric motor, separating clutch and torsional damper, used to balance out rotational irregularities, within a compact installation space and with a maximum output of 90 kW.

Hybrid transmissions

The modularly designed hybrid transmission can also be upgraded to a plug-in variant. The electric motor is fitted in the transmission housing in place of the torque converter, without taking up, hardly any additional installation space.

LV hybrid system

An electric motor plus power electronics is used for mild hybrids. The e-motor can be used as a generator to convert braking energy into electrical energy (regeneration). Electric start-up and start/stop are also possible - with a maximum power output of 15 kW.

Electric motor

Drives for various vehicle concepts: From mild hybrid to plug-in hybrid. With a maximum power output of 55 kW.

Hybrid module

The turnkey solution for hybrid drives takes up very little installation space. The module integrates the electric motor, separating clutch and torsional damper, used to balance out rotational irregularities, within a compact installation space and with a maximum output of 90 kW.

ELECTRIC AXLE DRIVE

This prize-winning concept is ideally suited to small and compact cars. The motor, the transmission with differential, housing, cooling unit and the power electronics with control software form a unit with a maximum power output of 150 kW.

POWER ELECTRONICS

Efficiency and precision: These criteria are used by the power electronics to modulate and control the type, voltage and strength of almost all the electrical currents in the vehicle. The currents must reach the various consumers efficiently and precisely dosed – and, in return, optimally recharge the battery. It is therefore not surprising that the power electronics form the primary module, in other words the heart and brain, of the locally emission-free driveline.

ELECTRICALLY-DRIVEN TWIST BEAM AXLE

In this integrated drive and chassis concept, the wheels are individually driven. Two 40 kW e-motors are integrated in the rear axle close to the wheels. The torque can be distributed individually to each wheel.

MODULAR ELECTRIC REAR AXLE CONCEPT

Fully integrated system solutions reduce development outlay for customers. The electric motor is provided completely integrated in an axle system and the power electronics are already integrated in the drive. It can be used as a full hybrid in front-transverse drives with electric motors or as an electric four-wheel drive or even as a purely electric drive for battery-operated vehicles.