ZF is presenting new electrical drives for passenger automobiles and lightweight industrial autos. This newest technology of e-drives advances energy density and vitality effectivity as a consequence of quite a few improvements at each the element and system degree. These embrace the compact design of the drives, energy electronics, and a resource-saving use of supplies, which additionally makes the manufacturing of the drives extra sustainable.
ZF’s new electrical drive
With their modular idea, the brand new ZF e-drives help automotive producers in customizing the additional electrification of their complete mannequin vary. For finish clients, the brand new applied sciences provide greater effectivity, extra energy, and shorter charging occasions.
ZF’s new technology of electrical drives is predicated on a modular general idea with built-in electrical motor, inverter, transmission, and software program. With its excessive degree of interface experience and know-how for driving methods, ZF software engineers can meet buyer necessities totally. Nonetheless, the Group may even provide the progressive parts individually, on which its personal system resolution is predicated.
Thanks to stylish inner interfaces, the brand new, extraordinarily compact design permits system or element diversifications to be made with little effort. As well as, the design has very excessive structural rigidity, which permits superior noise habits.
—Dr Otmar Scharrer, Head of Improvement for Electrical Drive Applied sciences
The brand new technology of ZF e-drives will likely be obtainable available on the market as a whole system beginning in 2025; ZF will convey particular person parts into sequence manufacturing earlier. The next improvements at element degree make their contribution to the superior general system:
Energy electronics handle the balancing act between a excessive diploma of element uniformity and excessive adaptability. The individualization takes place on the chip degree: A discretely structured ZF inverter is constructed with particular person energy semiconductor switches. This modularity gives higher efficiency scalability than is feasible with complicated energy modules. As well as, ZF’s “discrete package deal expertise” requires fewer sorts of parts than utilizing typical energy modules.
With a brand new, extremely built-in e-motor, ZF will increase the facility density in comparison with the expertise at present obtainable out there. A brand new cooling idea and a brand new winding expertise play the decisive function right here. Because of the new cooling idea, ZF permits oil to circulate instantly across the copper rods—precisely on the level the place most warmth is generated throughout operation. Such extremely environment friendly cooling considerably will increase efficiency with the identical weight and set up house. The continual energy of the electrical motor is elevated to as much as 85% of the height energy.
E-Motor Stator with new braided winding
As well as, the usage of heavy uncommon earths could be largely allotted with, and the e-motor can thus be produced extra sustainably. The braided winding expertise developed by ZF, an extra growth of the hairpin winding, permits a complete of 10% much less set up house. The winding head alone is round 50% smaller than with typical approaches. Which means that round 10% much less uncooked materials is processed.
With its new coaxial discount gearbox, ZF transfers its know-how in planetary gearboxes to the following technology of electrical drives. Two built-in planetary gears not solely generate the specified axle ratio, but in addition embrace the totally built-in differential perform. In comparison with widespread offset ideas, the brand new resolution reduces weight and set up house necessities with out compromising effectivity, noise, and vibration.
Built-in differential gear
Excessive-voltage converters (DC-DC converters) play a central function in gasoline cell-powered electrical drives. They compensate for the low output voltage and the sturdy voltage drop at excessive load of the gasoline cells. The brand new high-voltage converter from the ZF energy electronics platform, which was developed for passenger automobile and industrial automobile purposes, has a prime worth of 99.6% when it comes to effectivity.
New excessive voltage converter