ZAwheel. Movement by Perfection

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1 Movement by Perfection The Royal League in ventilation, control and drive technology ZAwheel Efficient, silent, environmentally friendly the gearless electric in-wheel hub motor for city, airport, sightseeing and double-decker buses, commercial vehicles for cargo transportation and special vehicles in the field of underground mining

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3 Environmental technology from a leading German company People from around the world come into contact with products from ZIEHL-ABEGG every day. Elevators are powered by ZIEHL-ABEGG motors, subways are ventilated with ZIEHL-ABEGG fans and hybrid buses drive with generators from ZIEHL-ABEGG. Innovative ventilation technology, drive technology and control technology from ZIEHL-ABEGG are found in industrial plants, in wind power and other power stations, in large buildings such as the Allianz-Arena, in hospitals, in trains and in many other applications. ZIEHL-ABEGG is certified in accordance with DIN The family-managed company is the world s largest supplier of motors and electronics for SMB elevator manufacturers and is also the technology leader for large, industrial fans. At the headquarters in Künzelsau, 300 technicians and engineers work on innovations for the drive, ventilation and control technology of tomorrow. Over 3,700 staff are now employed at the 18 production sites, 28 subsidiaries and 100-plus sales offices around the world. It all began more than a century ago with the development and construction of electric motors. The company has deployed its expertise in the automotive sector since To do justice to the significance of e-mobility, in late 2011 ZIEHL-ABEGG founded the company ZIEHL-ABEGG AUTOMOTIVE, which has its head office in Kupferzell. ZIEHL-ABEGG is focussing its core competencies in the area of in wheel hub drives, axle drives and generators to provide the commercial vehicle industry with advanced solutions. Welcome to the best. Welcome to the Royal League. ziehl - abegg.c om 3

4 ZAwheel benefits the citizens, the environment and the operating organisations ZAwheel in wheel hub drive Silent, efficient, eco-friendly: The in wheel hub drive For the trend-setting concept of the electric in wheel hub drive, ZIEHL-ABEGG is taking advantage of its experience as the technology leader in the development of electric motors aimed at maximum performance with minimum energy consumption and is accomplishing exactly that in the tightest possible space. The benefits of having the drive directly in the wheel are convincing: The torque is exactly where the power is needed. Powerconsuming transmissions and differentials can be omitted. On top of that, the ZAwheel converts the braking energy directly back into electricity. The result is top efficiency and environmental friendliness. + Can be used for new vehicles and for retrofitting + Identical structure for left-hand and right-hand drive vehicles + Suitable for all electrical energy sources + Improvement of low-floor design + More space for the vehicle design + Improved driving comfort + Resource conservation + Elimination of approx. 80% of the moving parts in the drive train making it: + low maintenance + easy to maintain + eco-friendly + produce minimum noise characteristics (< 60 dba at 30 km/h) + Highest drive efficiency of approximately 90% (battery to wheel) + Regenerative operation (recuperative) + Minimum energy consumption: approx. 0,6... 0,8 kwh/km 4 ziehl-abegg.com

5 Impressive proof ZAwheel on Tour The EU-funded project ZeEUS Zero Emission Urban Bus System is coordinated by the Internal Association of Public Transport (UITP) and supported by the European Union. There are a total of seven European cities involved in the project, with Münster boasting five vehicles featuring ZAwheel. Recipient of international environmental and innovation awards The EU-funded project eliptic Electrification of public transport in cities comprises 22 city-based flagship projects that demonstrate various technical approaches for implementing electric public transport under different operational, geographical and climatic conditions. The ZIEHL-ABEGG demo bus with ZAwheel is being deployed across Europe in order to enable technical assessment of the electric drive train. Today, environmentally friendly mobility is a must. With the noiseless in-wheel hub motor ZAwheel, ZIEHL-ABEGG AUTOMOTIVE not only offers an environmentally friendly and highly innovative drive, it also delivers pioneering work in the field of electric mobility and always with the demand for maximum quality that has been recognised in the field of electric drives for over 100 years. This makes it all the more exciting for ZIEHL-ABEGG AUTOMOTIVE when recognised experts and institutions take note of this innovation and quality, with ZAwheel having received a number of international environmental and innovation awards in recent years. ziehl-abegg.com 5

6 The deployment of ZAwheel has many opportunities Articulated buses Solo buses Airport buses Double-decker buses Waste collection vehicles Special vehicles in underground mining 6 ziehl-abegg.com

7 An overview of the ZAwheel system structure The axle drive module from ZIEHL-ABEGG AUTOMOTIVE was specially developed for use as an electrically driven low-floor axle for city buses and can be used in solo buses as a rear axle drive, as well as in articulated buses as a rear axle drive (pusher) and/or as a centre axle drive (puller). In the case of articulated buses, the combination of two driven axles and single-wheel drive brings additional benefits in terms of tyre wear and traction. The concept of the low-floor axle system can be applied to serial hybrid buses as well as fully electric city buses (fuel cell, battery) and is designed with a maximum axle load of up to 13 tons. With the elimination of approx. 80 % of the moving parts in the drive train, the ZAwheel is the leading option in terms of: Total efficiency (battery to wheel) Noise characteristics Maintenance costs ziehl-abegg.com 7

8 The systems components in detail The drive concept is that of a gearless-free single wheel drive featuring a liquid-cooled permanent magnet synchronous motor (PMSM) with integrated power electronics. The integrated design helps ZAwheel solve an issue that is observed in many vehicles featuring only electric drive and that frequently occurs in the course of interaction between the electric motor and the power electronics. The power electronics convert the battery direct current to the three phase alternating current required for the electric motor. In this context, there is the potential for significant optimisation of the drive efficiency in certain drive cycles. The axle drive module consists of the low-floor frame, in-wheel hub motors with integrated power electronics and rims, brakes, brake disks, and sensors for the temperature, ABS, motor speed and tachometer. This means that a maximum drive output of 400 kw and a continuous output of 240 kw are available per axle, with the total efficiency of the drive system being 90% (battery to wheel). In addition to using in-wheel hub motors to drive the wheels, these can also be used as generators for regenerative braking (recuperation). The installation space and the fitting dimensions are compatible with common standard portal axles for low-floor buses, which spares having to make elaborate adaptations on the bus undercarriage. In addition, the vehicle manufacturer gains more flexibility when designing the bus. That all results in potential improvements on the vehicle, such as a wider tyre track, wider spring spacing and a wider middle aisle of up to 880 mm for the low-floor bus. The concept of this electrically driven low-floor bus in inner-city traffic with many stops and go s provides especially cost effective and eco-friendly deployment. One-stop expertise Axle drive module Thanks to the ZAwheel control unit, which was developed in-house, it is now possible to acquire all system components of the axle drive module from a single source. Containing hardware and software, the ZAwheel control unit manages the complex interplay of electric components and helps the electric drive system operate even more efficiently. 1 ZAwheel with integrated power electronics 2 Rim 3 Shock absorber 4 Chassis beam and cross beam for axle guidance 5 Low-floor frame and brake disks 6 Air suspension 7 Support arms for air suspension 8 Brake cylinder 1 8 ziehl-abegg.com

9 Axle drive module Vehicle type: City bus, airport bus Application: Solo/articulated bus Design: Low-floor bus Drive: Independent direct drive, gearless Axle load: kg Axle weight: 440 kg (without attachments) Sensors: ABS, tachometer Rim size: 22.5 x 8,25 Tyre size: 275/70R22.5 Efficiency: Approximately 90% (battery to wheel) In wheel hub drive ZAwheel V1.0 Voltage range: VDC Nominal voltage: 625 VDC Rated current: 230 A Rated power: 120 kw Rated torque: 3700 Nm Speed range: rpm Max efficiency: Approx. 92% Sensors: Temperature, speed Type of cooling: Water cooled Electronics: Integrated power electronics ziehl-abegg.com 9

10 Minimising the energy-demand and maximising the efficiency Conventional systems, such as central-motor and electric portal axle for hybrid and electric vehicles, are equipped with a multi-speed transmission, differential, summation or simple reducing gears. This is detrimental to noise, drive efficiency, energy regeneration, weight, space requirements and maintenance. ZAwheel, the gearless electric direct-drive with in wheel hub drives is consequently omitting any kind of transmission and has eliminated 80% of the moving parts in the drive train. The in wheel hub drives are placed exactly where the torque is needed and where it is most efficient directly in the wheel with a total efficiency of the drive system of 90% (battery to wheel). Central-motor Diesel motor/ electric motor Motor Gear Differential Axle Wheel Wheel hub close to motor Motor Gear Wheel In wheel hub drive Direct drive In wheel hub drive System comparison of different drive concepts for city buses Three drive concepts, central-motor, electric portal axle and in wheel hub drive, used in a 12 m electric bus with a daily mileage of 200 km on 340 days a year, have been compared by a bus manufacturer. The bus was equipped according to the current standard of the respective manufacturers and the selected driving cycle SORT2. To ensure comparability, the tyre pressure and the total/overall vehicle weight (m 14,410 kg) have been adjusted accordingly. The results were clear: Direct cost benefits Reduction of initial costs due to smaller battery pack (approx. minus 30 kwh) Reduction of annual operational costs thanks to low energy consumption (approx. minus 8,840 10,200 kwh) Further benefits of ZAwheel Average energy consumption [kwh/km] 1,20 1,10 1,00 0,90 0,80 0,70 0,60 0,50 0,40 0,30 0,20 1,06 116,48 1,04 114,29 0, Average energy consumption [%] Minimum installation space requirements 0,10 10 Weight reduction Low maintenance Minimum noise characteristics 0,00 Central-motor Electric portal axle ZAwheel 0 10 ziehl-abegg.com

11 The comparison demonstrates: ZAwheel is the eco-friendly future Significant reduction of environmental noise With the EU Environmental Noise Directive 2002/49/EC, there is a common European approach to reducing the noise disturbance caused to the public. Noise reduction relates to strategies that prevent, deflect and decrease road traffic noise. The aim is to tackle noise at the source of the emissions. The disturbance caused by environmental noise is determined using noise maps. The noise maps are used in turn to set up noise campaign plans, which define measures for reducing the noise disturbance experienced by the public. One potential option for reducing vehicle noise emissions is the procurement of low-noise vehicles. A 10.5 m Euro 6 diesel bus was compared with a 12 m electric bus driven by ZAwheel in two typical driving situations: Bus stopping at a bus stop (bus approaches, stops and then drives off again) Bus driving past the bus stop at 50 km/h The results are striking: Thanks to the use of the electric bus, it was possible to reduce the environmental noise by approx. 16 db(a) when stopping at the bus stop and by approx. 8 db(a) when driving past the bus stop. In the local public transport system, the use of low-noise vehicles (serial hybrid buses, fuel cell buses and battery buses) makes a considerable contribution to reducing noise levels in inner cities. The gearless-free electric direct drive ZAwheel is particularly suitable in this regard, as it features minimal noise characteristics due to the elimination of approx. 80% of the moving parts in the drive train. This has been officially verified to impressive effect by means of a noise measurement* carried out in a residential area. The base noise level was 50 db(a). * Noise measurement performed on 7 November 2014 in Kupferzell by the Hohenlohe district administration Overview of the results: Diesel bus db(a) Electric bus db(a) Bus stop simulation 72,5 56,1 Drive-past simulation Highest travel comfort Fully electric city buses use the gearless-free electric direct drive ZAwheel to accelerate immediately to the desired driving speed in a powerful manner without tractive effort interruption this provides greater comfort for passengers and further assistance for the driver with regard to the task of driving. In addition, ZAwheel is almost noiseless the tyres are the only significant source of noise. Measurements of the interior noise level performed on city buses (e.g. 12 m with 3 doors) featuring ZAwheel demonstrate a considerable reduction in the interior noise level compared with conventional electric drive systems (central motor or electric portal axle): Speed 0 km/h bus stop (idle) At 30 km/h Driver's seat 47.8 db(a) 58.9 db(a) Centre door 45.7 db(a) 60.4 db(a) Rear door 48.7 db(a) 59.4 db(a) ziehl-abegg.com 11

12 Vehicle manufacturer In our role as a system supplier, we are a primary automotive supplier and we supply complete electric axle drive modules consisting of a rim, control unit, in-wheel hub motors with integrated power electronics, low-floor axle and add-on parts (spring beam, longitudinal beam and cross beam) to bus manufacturers including: VDL / Netherlands UNVI / Spain Hybricon / Sweden Ekova Electric / Czech Republic Troliga Bus / Slovakia ebe-europa / Germany Fuel Cell Electric Bus Battery Electric Bus URSUS / Poland 12 ziehl-abegg.com

13 New vehicle or electrical retrofit: Retrofitting existing commercial vehicles as an advantageous alternative In Europe, diesel engines are the main drives for trucks and buses. Around the world, reliable engines power the city, airport, sightseeing or double-decker buses plus municipal commercial vehicles and special vehicles in underground mines. Despite the many advantages, diesel engines emanate large amounts of toxic particles and nitrogen oxides and cause significant noise emissions. So a large part of urban air pollution from existing fleets is caused by old, heavily polluting vehicles. A faster development towards better air quality is greatly hampered by the lengthy fleet replacement process, which can as long as 10 to 20 years. In addition, the current supply of zero-emission vehicles is still very limited and, for instance, all-electric zero-emission sightseeing buses are not available on the market. ZAwheel scores in many areas, starting with the initial decision: The choice between buying new or retrofitting existing vehicles already provides the first cost advantage. When retrofitting existing vehicles, basically the drive train is replaced by the axle drive module and the required electrification is undertaken. Thanks to the significantly lower operating costs of ZAwheel compared to conventional systems, the acquisition or conversion costs are amortized in the foreseeable future. ZIEHL-ABEGG AUTOMOTIVE and its partners have demonstrated their strength in the various mobility sectors: the great reduction of unwanted emissions while retaining the vehicle s performance. However, any changes in the statutory regulations, such as the introduction of environmental zones, create an urgent need for action to be able to continue to operate these vehicles. Fleet operators have reacted globally by using zero-emission vehicles in order to totally avoid air pollution and noise emission. City bus e-busz in Rotterdam / Netherlands City bus The Whisper in Apeldoorn / Netherlands Foto: BVG, Knoke Sightseeing-Bus 12 m retrofit bus (Volvo 7700) as an airport shuttle in Umea Sweden ziehl-abegg.com 13

14 Simply convincing The ZIEHL-ABEGG AUTOMOTIVE comprehensive service Individual, professional advice and extensive service are the strengths of ZIEHL-ABEGG AUTOMOTIVE. Based on detailed industry knowledge and trustful cooperation with our customers, we are able to provide the ideal drive module for every application in the commercial vehicle sector. Service Training and consultation As new developments come into operation, it is important to turn this crucial moment into a successful one. We offer in addition to the support during the commissioning a wide range of comprehensive services: With our training and consultation solutions in electric drive technology, a great deal of knowledge can really get things moving. Support for the mechanics by a specially trained field service Acceptance of new projects Measurement and troubleshooting as service support Repairs Spare parts Repairs must be performed efficiently and with exactly the right expertise. Our specialists provide you with a detailed report and a personal quote. 12 month warranty inclusive Personal quote according to complexity based on analysis Product in top technical condition with genuine spare parts For electric motors: test bench test and replacement system Speed and competence are the hallmarks of the ZIEHL-ABEGG spare parts service. Sophisticated logistics Genuine spare parts in manufacturer quality Spare parts even after series discontinuation Complete components and sealing sets/spare part kits Wearing parts 14 ziehl-abegg.com

15 Vehicle monitoring Online and in real-time ZAwheel relies on two systems to achieve improved range and greater reliability of the vehicle while simultaneously reducing maintenance costs and experiencing less unplanned downtime: Online vehicle energy management Real-time vehicle monitoring The energy management system automatically and actively improves and stabilises the range of the electric vehicle. This makes it possible to respond to the respective energy requirements in advance and actively intervene in consumption or recharging. The energy management system provides a precise online range forecast covering the entire daily use. ZAwheel and the telediagnostics system are perfectly tailored to one another. All vehicle functions are inspected online. The real-time analyses allow reliable advance detection of irregularities, enabling a proactive response. The system offers a new dimension for transparency when performing diagnostics, analysis and monitoring of your buses. Route analysis ZAwheel real-time analysis System features: Online remote diagnostics including active energy management All parameters in real time Precise fault localisation Comprehensive analysis functions at various levels Predictive maintenance possible Authorization concept for data access ziehl-abegg.com 15

16 ZIEHL-ABEGG AUTOMOTIVE GmbH & Co. KG Günther-Ziehl-Str Kupferzell ziehl-abegg.com ZIEHL-ABEGG AUTOMOTIVE GmbH & Co. KG EN - MA - 10/ Klunker & Ewald. This brochure contains information for your guidance. No guarantee is provided with regard to the accuracy of all information and no legal claims may be derived from this. Reproduction of this information, or extracts thereof, is permitted only with written approval.