Electrifying: ZF Pushes Forward With Plug-In Hybrids and All-Electric Drives

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1 Page 1/5, September 15, 2015 Electrifying: ZF Pushes Forward With Plug-In Hybrids and All-Electric Drives With two different drive concepts for all-electric subcompact and compact cars, ZF combines zero local emissions with dynamic motoring New ZF plug-in hybrid transmission increases efficiency, range, and the electric top speed ZF offers system components including power electronics from a single source The combination of tighter carbon dioxide targets and growing competitive and cost pressure, along with ever greater customer expectations calls for specific electric drive expertise: ZF offers this expertise with a modular approach that meets all the requirements in terms of functionality as well as vehicle manufacturers' commercial requirements. The ZF portfolio includes all components for the cost-effective electrified driveline including control units and power electronics, starting with individual hybrid modules, plug-in hybrid systems, through to allelectric concepts. These all-electric concepts include a drive module, which produces up to 150 kw, located centrally on the axle, as well as the etb (Electric Twist Beam), which incorporates two electric motors close to the wheel in a semi-independent rear suspension. Electric vehicles will need to be at least as affordable, costeffective, powerful, comfortable, and also capable of covering long distances as their respective counterparts with combustion engines or hybrid technology if they are to gain widespread acceptance rapidly in the marketplace. In order to speed up this development, ZF is rolling out two groundbreaking concepts at the same time. The first comprises a drive module positioned centrally on the axle; this module features an electric motor configured as a highrevving asynchronous motor. The electric motor, the single-speed transmission complete with differential, housing, and cooling unit, as well as the power electronics complete with control software

2 Page 2/5, September 15, 2015 form an integrated, extremely compact unit. Consequently, the complete drive module only weighs 113 kilograms. The highrevving concept up to 13,000 revolutions per minute are possible enables up to 150 kw of power to be generated. The drive's impressive axle torque of 3,500 Nm produces a maximum motor torque of 380 Nm from a standing start. ZF managed to address the resulting challenges placed on the noise characteristics associated with the high-revving concept by utilizing a single-speed transmission solution already proven in volume production, which, together with the effective integration of the electric motor, virtually eliminates all occurring vibrations. The technology company is now further developing the drive system into a modular kit for various vehicle and performance classes ready for volume production. A downrated version demonstrates what is possible in practice: With 90 kw it accelerates a subcompact prototype from zero to 100 km/h in about nine seconds with zero emissions locally and virtually no noise. The electric Twist Beam (etb), which ZF is now presenting as an optimized version in the prototype stage, constitutes an equally attractive alternative for microcars and subcompact cars in particular. The innovation essentially comprises a semiindependent rear suspension with a compact drive unit on the left and right wheels the drive unit in turn consists of an electric motor and a transmission in a lightweight aluminum housing. Each of the two motors currently supplies 40 kw. Further major benefits of this concept come courtesy of torque vectoring which allows the two motors to distribute the torque directly to individual wheels. The concept also saves valuable installation space. Compared with conventional systems, the subframe and various axle components, for instance, are eliminated, thus providing manufacturers with a great deal of additional design leeway in the center of the vehicle.

3 Page 3/5, September 15, 2015 Uncompromising interim step: ZF plug-in hybrid transmission The technology company has achieved the aim of all-electric, locally zero-emission motoring without limiting the overall range for volume production vehicles thanks to its plug-in hybrid transmission. This unit is based on the advanced 8-speed automatic transmission (8HP) which replaces the torque converter in its housing with an electric motor generating up to 90 kw peak power and 45 kw continuous power and virtually without taking up any additional installation space. Its additional power is sufficient to achieve all-electric speeds of up to 120 km/h the combustion engine only kicks in at higher speeds. The ZF drive also provides plug-in hybrid vehicles with a much greater range of up to 50 kilometers in all-electric operation, depending on the installed battery system. In the case of hybrids, the existing drive power can only be efficiently used to the full if precisely matched power electronics supplement the hardware. ZF is therefore also pursuing an end-toend systemic approach in this respect and is developing the software in-house for the entire hybrid management including control units and power electronics. Full design leeway the ZF modular hybrid kit ZF also offers suitable solutions for automotive manufacturers looking for just modules or individual components rather than complete systems. Providing appropriate basic transmissions are used, virtually any individual solution can be realized thanks to the modular hybrid kit. The mild, full, and plug-in hybrid applications, whose core element is an electric motor, can thus be developed with a high percentage of identical parts and major synergies leveraged as a result. ZF hybrid technology is already a compelling proposition in numerous volume production vehicles.

4 Page 4/5, September 15, 2015 Captions: 1.) ZF's electric drive module positioned centrally on the axle provides a mechanical output of up to 150 kw and high torques already at low speeds. 2.) The electric motor, single-speed transmission complete with differential, housing, and cooling unit, as well as the power electronics complete with control software form an integrated, extremely compact unit. 3.) etb (Electric Twist Beam): The overall system consisting of axle and electric drive is a ZF development project specifically for subcompact cars and microcars. 4.) The 8-speed plug-in hybrid transmission from ZF: The electric motor, clutch(es), torsional vibration dampers, and hydraulics are integrated efficiently and compactly into the transmission. 5.) The compact power electronics control the flow of energy in the hybrid system's electric drive and in the vehicle power supply. 6.) The ZF hybrid module integrates the electric motor, momentum start clutch, damping system, and actuation unit. The full-hybrid module supports all-electric motoring. Photos: ZF Press contact: Robert Buchmeier, Technology and Product Communications, phone: , robert.buchmeier@zf.com Thomas Wenzel, Head of Technology and Product Communications, phone: , thomas.wenzel@zf.com

5 ZF is a global leader in driveline and chassis technology as well as active and passive safety technology. The company, which acquired TRW Automotive on May 15, 2015, is now represented at about 230 locations in some 40 countries. The two companies, which were still independent in 2014, achieved a sales figure exceeding 30 billion with 134,000 employees. As in previous years, both companies have invested approximately 5 percent of their sales in Research and Development (recently 1.6 billion) in order to be successful with innovative products. ZF is one of the top three automotive suppliers worldwide. Page 5/5, September 15, 2015