Zero-Emission Future: ZF Electric Drives for Passenger Cars

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1 Page 1/5, Zero-Emission Future: ZF Electric Drives for Passenger Cars Electric axle module can be used as an efficient drive for purely electric subcompact and compact cars or as an electric rear axle in the axle hybrid etb development project: Integral system comprising rear axle and electric drive delivers benefits in terms of driving dynamics and design ZF solutions combine zero-emission mobility with a dynamic driving experience ZF uses its expertise in driveline electrification: The technology company has developed an electric drive for small and mid-sized passenger cars. The drive is tailored to future requirements in urban traffic the drive module, which is located in a central position on the axle, develops 90 kw of mechanical power and high torque right from low speeds. At the North American International Auto Show (NAIAS), ZF displays a newly configured drive concept version with enhanced features: The power electronics is now integrated in the electric axle drive and the output power has increased to 120 kw. ZF is presenting another development project relating to the electric drive the Electric Twist Beam (etb), an electric car driveline integrated into a semi-independent rear suspension: The left and right wheels include a compact drive unit which combines a transmission and an electric motor in a single lightweight aluminum housing. The ZF electric axle drive module consists first and foremost of an electric motor which, as an asynchronous motor, does not require any rare earth elements such as neodymium or dysprosium. Added to which are a compact one-speed ratio unit, the power electronics, and the control software. Thanks to the two-stage transmission and innovative high-speed design the electric motor with energy conversion efficiency that has been optimized for everyday usage reaches 21,000 revolutions per minute -- it is possible to achieve

2 Page 2/5, superb performance while using less material. Upon start, the compact drive creates a torque of 1,700 Nm on the vehicle axle. So the car accelerates from 0 to 100 km/h in nine seconds. A maximum of 90 kw is available on the axle. Loss-free conversion By offering the electric axle drive, ZF has also solved a problem of many purely electrically powered vehicles as the interaction between electric motor and inverter can lead to losses in certain driving cycles. ZF is capable of minimizing these losses by optimizing the electric system as a whole, thus increasing the range by up to six percent. The electric axle drive, which weighs 45 kilograms and sets the benchmark in terms of power density, is currently a development project that ZF intends to fine-tune until it is ready for standard production. Even more powerful in the future On display at the NAIAS, is a re-configured, enhanced version of the electric axle drive from ZF: The output power of the electric motor was increased to 120 kilowatts and 2,500 Nm of axle torque. The integrated power electronics is another highlight of the axle drive module's further development toward a true electric axle drive system. At the same time, ZF is working on a modular system with various power classes to optimally meet the requirements of various customers and models. In the uprated variants, the ZF system is no longer the preserve of subcompact and compact cars: In the form of an axle hybrid module the electric drive innovation is also suited to front-wheel drive vehicles through to the mid-size luxury segment. Electric Twist Beam (etb) electric drive and twist beam rear suspension functionally integrated At the NAIAS, ZF highlights the prototype of the etb, which had previously been showcased as a concept--with key aspects that have been fine-tuned. The essence of etb is an electric car driveline integrated in a semi-independent rear suspension: The left and right wheels include a compact drive unit which combines a transmission and an electric motor in a single, lightweight

3 Page 3/5, aluminum housing. Another special design feature used by ZF on the etb consists of a polygon press-fit connection to join the aluminum trailing links with the steel transversal section. This ZF innovation is designed specifically for microcars and subcompact cars: Each of the two electric motors generates 40 kw, producing a total output of 80 kw one third more than the original concept with the same installation space requirements. Two separate drives also provide wheel-specific torque vectoring. This enhances both driving safety and driving dynamics. ZF has taken over the weight-saving high-speed design from its central electric axle drive module, making use of all synergies. The arrangement of the motors also limits the effects on the unsprung masses. The intelligent function integration reduces the required installation space: For instance, the subframe for a central motor that is fixed to the body and mechanical drive components, such as side shafts, are no longer necessary, freeing up a great deal of space in the center of the vehicle. Manufacturers are able to make use of this extra space for their own vehicle design features. The body connection points for the etb are comparable with those on conventional axles, ensuring easy integration into existing model platforms. It would also be possible to use the braking system and rim dimensions as those used in the corresponding standard combustion-engine vehicles.

4 Page 4/5, Captions: 1.) ZF's electric drive module undergoing on-road testing: Zeroemission, efficient driving dynamics, thanks to high power density. 2.) The electric drive module, which is located in a central position on the axle, has 90 kw mechanical power and high torque even at low speeds. 3.) The core of ZF's electric axle drive is an electric motor and an integrated ratio unit. 4.) ZF system solution: The PUM-X45 inverter has been optimized for the electric axle drive module. Its compact design makes it easy to integrate into the vehicle. 5.) Electric Twist Beam (etb): The overall system of axle and electric drive is a development project that has been designed specifically for subcompact cars and microcars. Images: ZF Press Contact: Bryan Johnson, Senior Manager, Marketing and Communications, ZF North America Phone: ; bryan.johnson@zf.com Thomas Wenzel, Senior Manager Product Communication and Trade Press, Communications, ZF Group Phone: ; thomas.wenzel@zf.com ZF is a worldwide leading technology company in driveline and chassis technology with 122 production companies in 26 countries. In 2014, the Group will presumably achieve a sales figure of more than 18 billion with about employees. In order to continue to be successful with innovative products, ZF annually invests about 5 percent of its sales (2014: around 890 million) in research and development. ZF is one of the ten largest automotive suppliers worldwide. In 2015, the company will celebrate its centennial. Originally named Zahnradfabrik GmbH, ZF was founded in Friedrichshafen in 1915 by

5 Page 5/5, Luftschiffbau Zeppelin GmbH among others. In its early years, the company developed, tested and manufactured aircraft transmissions. After 1919, the company's focus shifted to the automotive and commercial vehicle industry under Alfred Graf von Soden-Fraunhofen, the first general manager and later head of the company. In this sector, the company registered numerous patents for innovative transmission technology and established itself once and for all as a major technology supplier. ZF grew outside of Europe in 1958 with a location in Brazil, launching a globalization drive that still continues. In addition, through product innovations and acquisitions, ZF constantly expanded its range of expertise. In 1984, ZF acquired the majority share in Lemförder Metallwaren & Co. KG, a move that extended the product portfolio to include chassis technology. In 2001, ZF took over the former Mannesmann Sachs AG to strengthen its value added product offering with driveline and chassis components. It adopted the current name of ZF Friedrichshafen AG in Today's product range includes driveline and chassis technology such as transmissions, driveline and chassis components, as well as complete axle systems and modules. ZF products are used in passenger cars, commercial vehicles, construction and agricultural machinery, rail vehicles and marine applications. The company also focuses on the wind power and electronic components business. In addition, ZF Services represents the company on the international aftermarket. In 2014, ZF announced its intention to acquire U.S. automotive supplier TRW. The shareholders of ZF Friedrichshafen AG are the Zeppelin Foundation, administered by the City of Friedrichshafen, holding a share of 93.8 percent, and the Dr. Jürgen and Irmgard Ulderup Foundation, Lemförde, with 6.2 percent. "Motion and Mobility," ZF s tagline, clearly states the company's core mission: Right from its foundation, ZF has developed and manufactured innovative products for all people around the globe who want to move things reliably, comfortably and safely all while experiencing the ultimate in efficient mobility. Quality, technological leadership and innovative power have always defined the company's identity today as much as ever. For further press information and photos please visit: