Into the Future – with E-Mobility

ZF products for hybrid and electric vehicles 2 E-Mobility Cars Electric Drive Technology 3 Content 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 01Electric Mobility designed for efficiency and are

04 Electric Mobility – A Megatrend with Potential 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 02Drive Systems

06 Diversity in Efficiency: the environment and resources. It is Electrification of the Driveline impossible to imagine automobiles Products 08 New Features thanks to 03 E-Mobility

09 48V Hybrid System of the future without ZF driveline 10 Electric Motor 11 Hybrid Module technology because, with its modern 12 Hybrid Transmission 13 Power Unit and reliable components, ZF is also 14 Electric Vehicle Drive 15 Modular Electric Rear Axle Concept 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 E-Mobility Cars Electric Drive Technology 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 experimen- are charged with green electricity their overall carbon Automotive manufacturers appreciate ZF’s expertise in ted with electric drives for the early automobiles. The footprint will improve considerably. Fuel cell vehicles are offering complete hybrid modules in which the electric fact that, in the end, a drive concept based on liquid also purely electrically driven. In this case, advantages in motor, a separating clutch, and torsional dampers which fuel gained from fossil fuels established itself and is terms of range result from the required energy generated balance out rotational irregularities of the combustion still in use today could soon prove to be only a phase on the road based on hydrogen or methanol stored in engine are integrated in very limited space. ZF uses in automotive history. The past decades have shown us tanks. these hybrid modules in its own systems, for instance the limits of fossil fuels: Global oil reserves will not be in the plug-in hybrid transmission based on the 8-speed available indefinitely, emissions caused by traffic dama- ZF: Solutions from a single source automatic transmission. ge the climate and the environment. In this context, the In the context of this electrification megatrend, automo- demand for individual mobility which is still increasing tive manufacturers can rely on the technology company For pure electric vehicles ZF supplies weight-saving fast, particularly in emerging industrialized nations or ZF. After all, ZF has been developing electric drives for electric axle drives which take up little installation space. “emerging markets”, can hardly be fulfilled based on vehicles for more than 25 years. In 2008, the company These include the electric motor, a two-stage spur combustion engine drive concepts. Legislators are also inaugurated the first industrial production facility for gear drive, as well as the power electronics system in starting to play an increasingly bigger role in this matter: electric motors for hybrid electric vehicles in Europe. one package. Its high speed design makes the system Globally, the automotive industry has to respect ever particularly efficient. Customers who buy electric drive stricter fleet consumption and emission limits. Therefore, Today electric drive components from ZF offer solutions systems from ZF benefit from the Group’s overall exper- alternative drive concepts for passenger cars are now for almost any passenger car manufacturer concept, tise. After all, ZF has valuable system know-how about and will be in high demand in the future – and for many starting with the development and production of electric the entire driveline, including its functional and structural of them, electricity as a power source plays an important motors with different power output figures for use in pa- integration into the automobile. The Group’s expertise in role: Hybrid electric vehicles combine the advantages of rallel hybrid concepts. The product portfolio ranges from the area of mechanics derived from its well-established electric and combustion-engine drives. integrated 48V solutions with 15 kW which can be used driveline technology product portfolio is equally valuable in mild hybrid systems and already offer a large number to ZF customers. It includes topics as complex as the Pure electric vehicles are already in use without causing of advantages of electric drives to powerful electric mo- damping of torsional engine vibrations or efficient torque any local emissions – and as soon as their batteries tors with up to 160 kW for plug-in hybrid transmissions. transmission. 6 E-Mobility Cars Electric Drive Technology 7 Drive Systems

Diversity in Efficiency – Overview of Electrified Drive Configurations HEV – Hybrid Electric Vehicles EV – Electric Vehicles Electrification of the Driveline

Full hybrid, parallel Mild hybrid, parallel Full hybrid, parallel Battery electric vehicle rear-wheel drive rear-wheel drive front-transverse drive 48V or high voltage

More cost-effectiveness and less or no emissions: This is a different model: In most cases, the combustion engine the objective when it comes to implementing almost all drives a generator which supplies energy for one or electrified passenger car drives. This goal can be achie- more electric motors for the axle or wheel drive. ved in different ways. Finally, in pure electric vehicles or EV, no combustion Fuel Cell In hybrid electric vehicles or HEV, the conventional engine is installed at all. The energy for the electric combustion engine is supported by at least one electric motor or motors is either supplied by a battery, as is the motor. Its respective capacity can be used for an initial case for battery electric vehicles or BEV; or a fuel cell on classification: A micro hybrid can, for example, switch board generates the electric energy by means of a che- off the combustion engine in a stationary vehicle (start/ mical reaction, as is the case for fuel-cell vehicles (fuel stop) as well as recuperate braking energy to a limited cell (electric) vehicle – FC(E)V). ZF works intensively on extent but does not actively drive the vehicle. The latter electric vehicle innovations, particularly with its complete Full hybrid Mild hybrid, parallel Serial hybrid Fuel-cell (electric) vehicle is possible starting with the mild hybrid in which an electric axle drive systems. front-transverse drive front-transverse drive or range extender electric motor for instance complements the gasoline or with electric motor 48V or high voltage diesel engine via the boost mode; it can, however, not A more powerful on-board supply system in passenger electric 4-wheel drive drive the car independently. This is possible in the full cars had already been a topic in the automotive industry hybrid which, as a plug-in hybrid electric vehicle (PHEV), before hybrid vehicles were introduced: After all, elec- can also be charged using any power outlet. It already trics and electronics mean more and more consumers tackles many everyday challenges purely electrically: A in the passenger car, taxing the classical 12V network Overview of Hybrid Categories PHEV equipped with the ZF plug-in hybrid transmission to the limits of its capacity. An additional 48V on-board even reaches speeds of up to 120 km/h and a range of supply system is also a less costly step toward hybridiza- Hybrid categories Micro Mild 48V Full (HEV) Plug-in (PHEV) up to 50 kilometers without generating any local tion. A mild hybrid system based on 48 Volts already ma- emissions. kes a large number of hybrid functions possible – sailing, Main functions Start/stop Start/stop Start/stop Start/stop boost mode, recuperation, electric starting, crawling, as (Boost mode) Boost mode Boost mode Boost mode As an alternative, HEVs can also be categorized based well as start/stop. Thanks to the low-voltage system, the (Recuperation) Recuperation Recuperation Recuperation on the interplay between the conventional combustion electronic components can, however, be integrated in (Electric maneuvering) Limited electric driving Electric driving engine and the electric motor: A hybrid in which both the vehicle at low cost. This results in fuel savings of 10 Sailing Sailing can influence the same driveline simultaneously and to 15 percent. directly, as is the case for the mild hybrid or PHEV, is a Type performance level 3-10 kW 15-25 kW 40-75 kW 75-160 kW 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 9

48V Hybrid System

Specification Permanent-field synchronous machine (PSM) Unit Drive configuration

Type PI286F10U1L50

Outer diameter 286 mm

Active length 50 mm

Voltage range 36 – 52 Vdc

Max. power mot. (10s) 20 kW

Max. power gen. (10s) 24 kW

Max. power mot. cont. 14 kW Mild hybrid, parallel Mild hybrid, parallel Max. power gen. cont. 17 kW front-transverse drive rear-wheel drive 48V or high voltage 48V or high voltage Max. torque cold @ 0°C @ 900A 205 Nm

Max. torque warm @ 120°C @ 800A 180 Nm Start/stop Switching off the combustion engine whenever it is not required reduces consumption. This is above all the Consisting of case when the vehicle is at a standstill. Today start/stop 48V Electric motor systems are therefore even integrated in vehicles without Highly integrated 48V inverter hybrid drive. New incl. rotor position sensor

Housing Recuperation Dog clutch (optional) When the vehicle decelerates, the electric motor is used Interface to transmission Electro-magnetic release system Features as a generator to convert the braking energy into electric (optional) energy and to charge the battery. thanks to Boost mode When full power is required in the hybrid vehicle, the electric motor supports the combustion engine. Advan- tage: For this reason, the latter can already be designed E-Mobility to be smaller and more fuel-efficient in hybrid vehicles – keyword: downsizing. Hybrid or pure electric Electric driving drives offer a number of As soon as electric motors drive the passenger car functions which make independently, no more emissions are caused locally Interface to optional while driving – and hardly any noise is generated. These torsional vibration damper Electric motor driving more efficient. are huge advantages, not least in inner city areas where strict access restrictions for vehicles with conventional drives are becoming more and more common.

Sailing Housing Power unit incl. rotor position sensor 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. 10 E-Mobility Cars Electric Drive Technology 11 Products

Electric Motor Hybrid Module

Specification Permanent-field synchronous machine (PSM) Unit Drive configuration Specification Permanent-field synchronous machine (PSM) Unit Drive configuration

Type AL280-32 Type AL280-80

Outer diameter 280 mm Outer diameter 280 mm

Active length 32 mm Active length 80 mm

Axial length module approx. 150 mm Axial length module approx. 240 mm

Voltage range 220 – 420 Vdc Voltage range 220 – 420 Vdc

Max. power 55 kW Max. power 90 kW

Max. torque 250 Nm Max. torque 400 Nm Mild hybrid, parallel Full hybrid, parallel Full hybrid, parallel Full hybrid, parallel Max. speed 7,000 rpm front-transverse drive front-transverse drive Max. speed 7,000 rpm front-transverse drive rear-wheel drive 48V or high voltage Max. torque separarting clutch 800 Nm

Consisting of Electric motor Torsional vibration damper Consisting of Rotor position sensor Electric motor Housing Torsional vibration damper Separating clutch Separating clutch actuation Electric motor Rotor position sensor Housing

Electric motor Separating clutch

Torsional vibration damper Interface to transmission

Interface to combustion engine Interface to combustion engine

Housing

Separating clutch actuation 12 E-Mobility Cars Electric Drive Technology 13 Products

Hybrid Transmission Power Unit

Product details electric drives

Specification Permanent-field synchronous machine (PSM) Unit Drive configuration Specification Power unit Unit Drive configuration

Type IL269-70 Type LE Gen4

Outer diameter 269 mm Volume 5 l

Active length 70 mm Max. voltage 450 Vdc

Axial length module approx. 150 mm Max. current 560 Arms

Voltage range 220 – 420 Vdc Continuous current 300 Arms

Max. power 90 kW Safety level D ASIL Fuel Cell Max. torque 250 Nm Full hybrid, parallel Max. speed 7,000 rpm rear-wheel drive

Consisting of Consisting of Electric motor Inverter Torsional vibration damper Separating clutch Signal connector Separating clutch Housing

Housing

High voltage battery connector

Interface to combustion engine

Torsional vibration damper

Electric motor

Cooling water connection Cooling water connection

Housing 14 E-Mobility Cars Electric Drive Technology 15 Products

Electric Vehicle Drive Modular Electric Rear Axle Concept

Specification Asynchronous machine (ASM) Unit Drive configuration An electric drive system integrated into the axle Drive configuration According to the customers, supplying driveline and Type eVD2 chassis technology from a single source has always been ZF‘s strength. This advantage also remains in times of Dimensions incl. housing 450 x 510 x 380 mm e-mobility. For instance, ZF offers the electric drive inte- Active length 150 mm grated into a complete axle system. For ZF customers, this considerably reduces development costs because Axial length module approx. 450 mm Fuel Cell ZF handles the coordination of internal interfaces. Voltage range 220 – 420 Vdc Fuel Cell ZF develops, fine-tunes, and tests the axle including Max. power 150 kW the electric drive, in accordance with the requirement Max. torque at axle 3,500 Nm specification. In the process, different axle types can be P1 configuration, P2 configuration, Fuel-cell (electric) used depending on the application. For this purpose, ZF Full hybrid Battery electric Max. speed 13,000 rpm parallel front- parallel front- vehicle provides a modular rear axle concept which is based on front-transverse drive vehicle Fuel-cell (electric) transverse drive transverse drive with electric motor vehicle including separation essential customer requirements. Since ZF can imple- electric 4-wheel clutch C0 for ment its experience with passenger car axle systems in drive Full-Hybrids and the process, the electric drive is integrated seamlessly Plug-In Hybrids Consisting of and according to the requirements. Electric motor Two-stage spur gear drive Power unit Power unit Parking lock Differential Housing

Electric motor

Parking lock

Two-stage spur gear drive Housing

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