Into the Future with E-Mobility ZF products for hybrid and electric vehicles
2 Content 3 01 Electric Mobility 04 Electric Mobility A Megatrend with Potential 02 03 Drive Systems Products 09 10 11 12 13 14 15 48V Hybrid System Electric Motor Hybrid Module Hybrid Transmission Power Electric Vehicle Drive Modular Electric Rear Axle Concept 06 Diversity in Efficiency: Electrification of the Driveline 08 New Features thanks to E-Mobility Innovative and fit for the future. Millions of people around the entire world are driving with car driveline technology from ZF today and in the future. The products are designed for efficiency and are simultaneously setting standards when it comes to comfort and driving dynamics. Vehicles equipped with ZF technology successfully walk the challenging line between the need to shape individual mobility while also doing everything possible to preserve the environment and resources. It is impossible to imagine automobiles of the future without ZF driveline technology because, with its modern and reliable components, ZF is also paving the way for many trends, such as electrification of the driveline. This culture of innovation as well as the ability to produce components of the highest quality has made ZF a valuable partner in the international automotive industry.
4 Electric Mobility Electric Mobility A Megatrend with potential Electric drives are an important element required to make sustainable mobility concepts possible. In this context, ZF provides innovative systems and components. Already more than 100 years ago, engineers experimented with electric drives for the early automobiles. The fact that, in the end, a drive concept based on liquid fuel gained from fossil fuels established itself and is still in use today could soon prove to be only a phase in automotive history. The past decades have shown us the limits of fossil fuels: Global oil reserves will not be available indefinitely, emissions caused by traffic damage the climate and the environment. In this context, the demand for individual mobility which is still increasing fast, particularly in emerging industrialized nations or emerging markets, can hardly be fulfilled based on combustion engine drive concepts. Legislators are also starting to play an increasingly bigger role in this matter: Globally, the automotive industry has to respect ever stricter fleet consumption and emission limits. Therefore, alternative drive concepts for passenger cars are now and will be in high demand in the future and for many of them, electricity as a power source plays an important role: Hybrid electric vehicles combine the advantages of electric and combustion-engine drives. Pure electric vehicles are already in use without causing any local emissions and as soon as their batteries are charged with green electricity their overall carbon footprint will improve considerably. Fuel cell vehicles are also purely electrically driven. In this case, advantages in terms of range result from the required energy generated on the road based on hydrogen or methanol stored in tanks. ZF: Solutions from a single source In the context of this electrification megatrend, automotive manufacturers can rely on the technology company ZF. After all, ZF has been developing electric drives for vehicles for more than 25 years. In 2008, the company inaugurated the first industrial production facility for electric motors for hybrid electric vehicles in Europe. Today electric drive components from ZF offer solutions for almost any passenger car manufacturer concept, starting with the development and production of electric motors with different power output figures for use in parallel hybrid concepts. The product portfolio ranges from integrated 48V solutions with 15 which can be used in mild hybrid systems and already offer a large number of advantages of electric drives to powerful electric motors with up to 160 for plug-in hybrid transmissions. Automotive manufacturers appreciate ZF s expertise in offering complete hybrid modules in which 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. For pure electric vehicles ZF supplies weight-saving electric axle drives which take up little installation space. These include the electric motor, a two-stage spur gear drive, as well as the power electronics system in one package. Its 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 into 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.
6 Drive Systems 7 Diversity in Efficiency Electrification of the Driveline Overview of Electrified Drive Configurations HEV Hybrid Electric Vehicles More cost-effectiveness and less or no emissions: This is the objective when it comes to implementing almost all electrified passenger car drives. This goal can be achieved in different ways. In hybrid electric vehicles or HEV, the conventional combustion engine is supported by at least one electric motor. Its respective capacity can be used for an initial classification: A micro hybrid can, for example, switch off the combustion engine in a stationary vehicle (start/ stop) as well as recuperate braking energy to a limited extent but does not actively drive the vehicle. The latter is possible starting with the mild hybrid in which an electric motor for instance complements the gasoline or diesel engine via the boost mode; it can, however, not drive the car independently. This is possible in the full hybrid which, as a plug-in hybrid electric vehicle (PHEV), can also be charged using any power outlet. It already tackles many everyday challenges purely electrically: A PHEV equipped with the ZF plug-in hybrid transmission even reaches speeds of up to 120 km/h and a range of up to 50 kilometers without generating any local emissions. As an alternative, HEVs can also be categorized based on the interplay between the conventional combustion engine and the electric motor: A hybrid in which both can influence the same driveline simultaneously and directly, as is the case for the mild hybrid or PHEV, is a parallel hybrid. And this is exactly the type of hybrid ZF focuses on for passenger cars. By contrast, the electric motors in serial hybrid drives are integrated according to EV Electric Vehicles Battery electric vehicle a different model: In most cases, the combustion engine drives a generator which supplies energy for one or more electric motors for the axle or wheel drive. Finally, in pure electric vehicles or EV, no combustion engine is installed at all. The energy for the electric motor or motors is either supplied by a battery, as is the case for battery electric vehicles or BEV; or a fuel cell on board generates the electric energy by means of a chemical reaction, as is the case for fuel-cell vehicles (fuel cell (electric) vehicle FC(E)V). ZF works intensively on electric vehicle innovations, particularly with its complete electric axle drive systems. A more powerful on-board supply system in passenger cars had already been a topic in the automotive industry before hybrid vehicles were introduced: After all, electrics and electronics mean more and more consumers in the passenger car, taxing the classical 12V network to the limits of its capacity. An additional 48V on-board supply system is also a less costly step toward hybridization. A mild hybrid system based on 48 Volts already makes a large number of hybrid functions possible sailing, boost mode, recuperation, electric starting, crawling, as well as start/stop. Thanks to the low-voltage system, the electronic components can, however, be integrated in the vehicle at low cost. This results in fuel savings of 10 to 15 percent. Fuel Cell Full hybrid with electric motor electric 4-wheel drive Fuel-cell (electric) vehicle Serial hybrid or range extender Overview of Hybrid Categories Hybrid categories Main functions performance level Micro Mild 48V Full (HEV) Plug-in (PHEV) (Boost mode) (Recuperation) Boost mode Recuperation (Electric maneuvering) Boost mode Recuperation Limited electric driving Sailing Boost mode Recuperation Electric driving Sailing 3-10 15-25 40-75 75-160
9 48V Hybrid System Permanent-field synchronous machine (PSM) Outer diameter 50 36 52 Max. power mot. (10s) 20 Max. power gen. (10s) 24 Max. power mot. cont. 14 Max. power gen. cont. 17 Max. torque cold @ 0 C @ 900A 205 Max. torque warm @ 120 C @ 800A 180 New Features thanks to E-Mobility Hybrid or pure electric drives offer a number of functions which make driving more efficient. Recuperation When the vehicle decelerates, the electric motor is used as a generator to convert the braking energy into electric energy and to charge the battery. 48V Highly integrated 48V inverter incl. rotor position sensor Dog clutch (optional) Electro-magnetic release system (optional) PI286F10U1L50 286 Switching off the combustion engine whenever it is not required reduces consumption. This is above all the case when the vehicle is at a standstill. Today start/stop systems are therefore even integrated in vehicles without hybrid drive. Interface to transmission Boost mode When full power is required in the hybrid vehicle, the electric motor supports the combustion engine. Advantage: For this reason, the latter can already be designed to be smaller and more fuel-efficient in hybrid vehicles keyword: downsizing. Electric driving As soon as electric motors drive the passenger car independently, no more emissions are caused locally while driving and hardly any noise is generated. These are huge advantages, not least in inner city areas where strict access restrictions for vehicles with conventional drives are becoming more and more coon. Sailing In driving situations requiring little power input, such as when driving at constant speed or slightly downhill, the combustion engine is switched off and the electric motor takes over vehicle propulsion if required. Interface to optional torsional vibration damper Power unit incl. rotor position sensor
10 Products 11 Hybrid Module Electric Motor Permanent-field synchronous machine (PSM) Outer diameter AL280-32 280 Outer diameter 32 approx. 150 Axial length module 220 420 Max. power 55 Max. torque 250 Axial length module Max. speed 7,000 Permanent-field synchronous machine (PSM) rpm 80 approx. 240 220 420 Max. power 90 Max. torque 400 Max. speed 7,000 rpm 800 Rotor position sensor actuation AL280-80 280 Max. torque separarting clutch Rotor position sensor Interface to transmission Interface to transmission Interface to combustion engine Interface to combustion engine actuation
12 Products 13 Hybrid Transmission Power Product details electric drives Permanent-field synchronous machine (PSM) Outer diameter Axial length module Max. power IL269-70 269 Volume 70 approx. 150 Power unit LE Gen4 5 l Max. voltage 450 Max. current 560 Arms 220 420 Continuous current 300 Arms 90 Safety level D ASIL Fuel Cell Max. torque 250 Max. speed 7,000 rpm Inverter Signal connector High voltage battery connector Interface to combustion engine Cooling water connection Cooling water connection
14 Products 15 Electric Vehicle Drive Dimensions incl. housing Axial length module Max. power Max. torque at axle Max. speed Two-stage spur gear drive Power unit Parking lock Differential Asynchronous machine (ASM) Modular Electric Rear Axle Concept evd2 450 x 510 x 380 150 approx. 450 220 420 150 3,500 13,000 rpm Fuel Cell P1 configuration, parallel fronttransverse drive P2 configuration, parallel fronttransverse drive including separation clutch C0 for Full-Hybrids and Plug-In Hybrids Fuel-cell (electric) vehicle Power unit Parking lock Differential Fuel Cell Two-stage spur gear drive An electric drive system integrated into the axle According to the customers, supplying driveline and chassis technology from a single source has always been ZF s strength. This advantage also remains in times of e-mobility. For instance, ZF offers the electric drive integrated into a complete axle system. For ZF customers, this considerably reduces development costs because ZF handles the coordination of internal interfaces. ZF develops, fine-tunes, and tests the axle including the electric drive, in accordance with the requirement specification. In the process, different axle types can be used depending on the application. For this purpose, ZF provides a modular rear axle concept which is based on essential customer requirements. Since ZF can implement its experience with passenger car axle systems in the process, the electric drive is integrated seamlessly and according to the requirements. Full hybrid with electric motor electric 4-wheel drive Battery electric vehicle Fuel-cell (electric) vehicle
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