Suspension system Page 6. Research and Development Page 16. The ZF Group Page 22

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1 Safety and Comfort Chassis Technology for Commercial Vehicles

2 Contents Chassis technology Page 4 Suspension system Page 6 Independent suspension Page 8 Steering system Page 12 Cabin suspension Page 14 Research and Development Page 16 Production plants worldwide Page 20 The ZF Group Page 22 2

3 Reliable in Quality and Technology For more than 60 years, ZF has been supplying innovative chassis products to manufacturers of trucks, buses, agricultural machinery, construction machinery, special vehicles, and rail vehicles. Within the ZF Group, we are the specialists for CV chassis modules. As a partner for added value in the commercial vehicle industry, we work with state-of-the-art technology and as a global leader offer our customers the best solutions in the product lines axle and wheel suspension, steering components and driver s cabin suspension. 3

4 Expertise in Chassis Technology Our design expertise guarantees fast implementation of growing safety requirements and increasing comfort standards. This is how we develop optimum chassis technology with outstanding safety standards the basis for problem-free transport of goods weighing several tons. Short development times from initial talks to components ready for production and strict compliance with technical specifications guarantee top customer satis faction. That s a promise. materials such as aluminum v-links or design improvements using die-casting technology for torque rods and v-links. Another way of reducing weight is function integration, achieved for instance with our 4-point links. These optimizations are aimed at reducing costs and improving driving dynamics. The focus here is on the chassis as a safety component. Lightweight chassis design We are committed to the permanent improvement of our products and processes. ZF optimizes lightweight construction with new materials and engineering processes, with innovative product design and extensive process experience. The business unit provides essential impetus for continuous weight reduction in commercial vehicle construction. Our product innovations increase the payload, reduce fuel consumption, and enhance the comfort of commercial vehicles. The result of this optimization is the use of lightweight Study: 4-point link made of fibre-plastic composite material ZF is working on manufacturing 4-point links from fibre-plastic composites instead of die-cast material. This drives forward developments both in functional lightweight construction and in the use of lightweight materials. In a corresponding concept study, we were able to construct a 4-point link using GRP, making a part that is some 25 percent lighter than the die-cast version. 4

5 4-point links in die-cast version Other PRODUCTS V-links with transverse lug V-links made of aluminum Torque rod in die-cast version Torque rod adjustable on both sides Chassis stabilizer 4-point links Study using glass fiber-reinforced plastic composite 5

6 Systemized Performance The suspension system What is already commonplace in other industries, such as aviation, has only recently been increasingly adopted in the commercial vehicle sector: lightweight construction to increase efficiency. In addition to the driveline, ZF has primarily been slimming down the truck chassis. Here, shedding a few pounds not only helps to reduce fuel consumption but also increases the loading capacity. Reduced unsprung masses in the chassis also translate into greater comfort and reduced wear on bearings. This is where ZF supplies the innovative rear axle suspension system as a complete solution. Function integration and lighter materials slash weights, both of 4-point links and of the overall system. Innovative twin rear axle suspension The cast version of the 4-point link is part of a weightoptimized truck suspension system for the rear twin axle. Here, the 4-point link is responsible for locating the non-driven leading axle with its weight-optimized hollow-cast design. The live rear axle features a stabilizer link with new polygon joining technology: Together with a lightweight aluminum v-link and a spring bellows carrier, it takes over both the axle guidance in longitudinal and transversal direction and the vertical axle load support. Thanks to the design enhancements on both axles, the new rear-axle suspension weighs far less, leading to less unsprung masses in the vehicle. This is of great importance for safety and comfort. Fleet owners benefit from a lower vehicle weight because then the payload can be increased and the relative fuel consumption reduced. Another positive side effect of the weight reduction is the reduced damage to the road surface, and lower wear of the chassis bearings. 6

7 Rear axle suspension Rear axle suspension for twin axles with 4-point link as well as v-link and stabilizer link Other PRODUCTS Rear axle suspension with stabilizer link and aluminum v-link Rear axle suspension with 4-point link Rear axle suspension with stabilizer link Rear axle steel suspension 7

8 Competence in Innovation and Comfort Independent suspension components. More safety and comfort in commercial vehicles. The demand for even better passenger comfort in buses requires new axle suspension concepts. That is why ZF started developing independent suspension systems according to the principle of double-wishbone axles at an early stage. This successful concept is set to be applied increasingly in trucks as well as special vehicles because the benefits in terms of safety and comfort apply here as well. Within the ZF Group, we are able to develop and supply complete systems including suspension systems, spring suspensions, damping, and brakes for front and rear axles. ZF your development partner. Cooperation within the ZF Group is a given, but ZF is also a development partner for many systems suppliers worldwide. We develop and supply ready-to-install modules for the axle systems of our customers. We cooperate intensively with our customers from development to volume production. We take on the development work right through to the design of efficient logistics concepts to give our customers the space to focus on their business. Zero maintenance, low noise ZF links are maintenance-free and low-noise. They come with the options of molecular or plain bearings and are made with precisely defined rigidity. That not only dampens vibrations, but also systematically produces elastokinematic properties. 8

9 Control arms for independent suspensions Other PRODUCTS Suspension joint for control arms Control arms in die-cast design Control arms in die-cast design Control arms for driven axles in special vehicles Control arms for driven axles in special vehicles Corner module for special vehicles 9

10 Innovation leap: ZF independent truck suspension The new independent front suspension for heavy-duty trucks significantly increases comfort and improves handling. Smaller unsprung masses and ideal damping reduce fuel consumption and wear. Comfort, efficiency, reliability - based on these standards, ZF developed its new IS 80 TF independent suspension for heavy trucks. It weighs 40 kg less compared to the current air spring rigid axle which is guided by control arms. This is also a weight advantage of more than ten percent compared to the current independent suspension. This was achieved by further developing the steering knuckle support principle. The control arms have been extended towards the king pin and have been directly connected to it. The spring forces are now supported by a separate, compact spring carrier. For this reason, the steering knuckle support could be omitted completely. This reduces the unsprung masses, enhances the axle kinematics, and allows for larger suspension travel. Like this, road bumps can be more easily compensated by the chassis, which reduces the stress for vehicle and driver. Especially in long-distance traffic with heavy trucks, high comfort is a central criterion for a workplace that reduces tiring and protects the driver s back. The axle halves of the independent suspension are designed as pre-assembled units. The kinematics and installation space consider the ladder-type chassis typical for trucks as well as the space requirements of the driveline. Furthermore, large steering angles guarantee an ideal turning radius. The development target, however, was not only to improve the driving comfort, but also to 10

11 protect the road surface. Apart from the smaller unsprung masses, the Air Spring Damper Module (LDM) by ZF contributes to this target as it enables an ideal damping and chassis suspension with the lowest possible demand for installation space. Like this, transport goods arrive at the end customers without any damage even in case of poor road conditions. Thus, the IS 80 TF independent suspension sets new standards for a more economic way of transporting goods. The lower total weight saves fuel and keeps the emission values on a low level. The design considers the truck s available installation space and offers the vehicle manufacturer good conditions for integrating modern chassis technology. 11

12 Benchmarks in Design and Service Life Steering systems. Our philosophy: simply the best solutions for you. Customized solutions and ready-to-install products for commercial vehicles have to meet high requirements. For example excellent quality and cost-effectiveness, reduced weight, integration of functions, and the latest technology. This is what the global market expects from us. ZF has the right responses to these requirements. We find the ideal solution even for the most challenging installation spaces. Using state-of-the-art development and manufacturing tools, we meet our customers demands. Innovative products from ZF When it comes to our proven ZF joint design or our fine-tuning system for tie rods and drag links, we set the benchmark. We stand for zero maintenance, low weight, and space-saving design. Also high on our list of priorities are reliability and long service life. commercial vehicles has achieved high market success. The successful product sets new standards with its low weight and space-saving dimensions, and impresses with improved wheel guidance behavior and reduced noise. Meanwhile, well over 15 million joints have already left the shop floor at the ZF Dielingen location. Custom solutions Whatever your requirements, we find the best solutions. Take for instance our lubricated joint developed especially for the North American market. It builds on the maintenance-free design of joint components that has proved its value millions of times over. This designto-market solution means customers can choose either the maintenance-free or the lubricated version. Since the start of high-volume production in 2000, the new ZF joint design for tie rods and drag links in 12

13 Steering rod for connection of steering axles Other PRODUCTS Tie rod with bend Tie rod with offset housing Tie rod with fine-tuning system Tie rod with inner ball joint Offset housing Fine-tuning system 13

14 Comfort for the Driver s Cab Innovative cabin suspension ZF cabin suspensions ensure driver comfort and optimize both functions and space. Good working conditions in commercial vehicles are not a luxury but a prerequisite for getting the driver, vehicle, and goods safely to their destination. As a systems supplier, ZF develops and produces cabin suspensions for all applications in commercial vehicles including springs, vibration dampers, and rubbermetal components. Every time, we offer you the optimal solution customized to your requirements. Drivers benefit from a more comfortable workplace with fewer jolts, pitching, or rolling motions. The various commercial vehicle fields of operation require different cabin types that in some cases differ widely in terms of dimensions, features, and weight. Comfort and optimized use of space ZF develops cabin suspensions for various requirements. The result? Good working conditions for drivers.just like the commercial vehicles themselves, the cabin suspensions are designed for very different appli cations. The requirements range from robust off-road capabilities, e.g. for construction vehicles or tractors, to comfort-optimized designs for long-distance driving on freeways. Expansion of our cabin suspension product line In 2012, we significantly expanded our cabin suspension product line. Now, even more joining technologies have been added to our proven polygon pressed joint method for driver s cabin anti-roll bars. This means we can offer our customers new product versions. Apart from conventional welding, we also use the innovative Magnetarc welding process. It enables us to weld different metallic materials together. That results in high-strength, high-tightness adhesive connections. 14

15 Driver s cabin suspension system with passive roll stabilization Other PRODUCTS Driver s cabin anti-roll bar with polygon pressed joint Driver s cabin anti-roll bar with welded joint Driver s cabin anti-roll bar with Magnetarc welded joint Driver s cabin suspension system with rear active roll stabilization system Driver s cabin suspension system with front active roll stabilization system 15

16 Research and Development to Secure Mobility Innovations not an end in themselves! They must pay off: for manufacturers, fleet owners, and drivers, but also for the environment and society. In view of these conflicting criteria, each new development must prove worthwhile. The ZF Group benefits from an international network of development centers: The main development locations are Friedrichshafen, Dielingen, Passau, Schweinfurt, Schwäbisch Gmünd, Northville near Detroit (USA), Pilsen (Czech Republic), and Shanghai (China). Worldwide, approximately 5,400 engineers work in Research and Development. Corporate R&D coordinates and supports the activities at the development center in Tokyo (Japan). Every year, ZF invests approximately five percent of its sales in Research and Development. With success, because innovative products from ZF set the standards for state-of-the-art technology again and again. Development work at ZF is organized according to decentralized and central functions. The divisions and business units focus on markets and product expertise, ensuring customer-centered, competitive technological product development. Corporate R&D works with a strong emphasis on basic research and theory and supports the functional development areas in the divisions. The fast and precise way to optimal solutions The CV Chassis Modules Business Unit develops complex products in Dielingen with cutting-edge technology and according to the latest methods. Included here are 3D-CAD, FEM (linear and non-linear), FEM according to the principle of organic growth (CAO), shaping simulation, and MBS. Our 3D-CAD system supports short development times worldwide, plus precise compliance with technical specifications. The rapid adoption of our customers and suppliers models is a major step toward the best solutions. Safety thanks to state-of-the-art technology Safety and quality due to prototype construction and component testing: The development of inno-vative solutions at ever-shorter intervals is crucial for the commercial vehicle industry. Supported by the application-oriented prototype construction and effective component testing at ZF, our customers are always on the safe side. Our experience and expertise pays off for our customers. The quality of our products is vital for people who are dependent on their functional safety. We carefully plan quality from the outset in the concept phase and ensure it is included throughout all phases. Audits, also according to TS 16949, regularly confirm this. Because we implement a comprehensive quality management system, you can rely not only on quality, but also on service and cost-effectiveness. 16

17 Multiaxial test bench for CV axle systems On the test bench, commercial vehicle chassis modules are tested under simulated conditions analogous to those during daily truck operation on the road. The test bench can apply loads of up to 36 tons onto the axle. With the test bench, ZF is able to develop and test entire axle suspension systems. development Center Development location Dielingen Concept and design development CAD representation Multi-body simulation (MBS) Measuring wheel Measured data recording under realistic conditions Development department 17

18 CV chassis modules in various types of commercial vehicles and industries Innovation support truck chassis From vans to 9-axle heavy-load cranes, from tractors to high-speed trains. We supply our products for various applications to a whole range of industries. Today s chassis systems must perform ever better. Not only in commercial vehicles or buses. Higher top speeds combined with off-road capabilities, these are properties required of independent suspension solutions for construction and agricultural vehicles. The rail industry also benefits from our solutions. Our vibration-absorbing torque supports as well as flexible joining components reduce wear on materials and save weight. They ensure safe comfort at high speeds. That guarantees perfect, reliable, and sustainable products. ZF is committed to the mobility of people and goods. Innovations that move you chassis modules from ZF. 18

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20 Production Plants for CV chassis modules: Your Partner Worldwide Global synergies create clear benefits. Wherever our customers require our services, ZF is there for them. Furthermore, as part of the ZF Group, we offer our customers the synergies of a globally leading supplier of Driveline and Chassis Technology for the automotive industry. We are at home with all the instruments of global sourcing. Effective project management with the support of efficient suppliers guarantees competitive prices and quality. By producing chassis modules in Gainesville, Georgia (USA), Sorocaba (Brazil), Ermua (Spain), Izmir (Turkey), Shanghai (China), and in future also in Pune (India), we offer our customers global presence. They also benefit from the worldwide locations of the entire ZF Group. Because we are present on local markets, we respond to the product requirements of local customers, designing for the market. Thanks to far-reaching synergy effects, we are the leader in many technologies connected with commercial vehicle chassis and steering systems. Our development potential, production know-how, and logistical competence are at the service of commercial vehicle manufacturers the world over. 20

21 worldwide Locations Dielingen Germany Gainesville USA Ermua Spain Izmir Turkey Sorocaba Brazil Pune India Shanghai China 21

22 The ZF Group 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 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. 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. 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. 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. 22

23 ZF Friedrichshafen AG CV Chassis Modules Dr.-Jürgen-Ulderup-Straße Stemwede Germany Phone Fax EN Edition 2014