1.2016 MICHIGAN 1. 2016 Where cars learn to drive DIGITIZATION Silent revolution THE ZF MAGAZINE INDUSTRIAL TRANSMISSIONS THE ZF MAGAZINE Driving giants SWITCHED ON E-POWER SPECIAL EDITORIAL SENSOREN o you drive an electric car? The enor- we are sending out another clear signal confirming AN mous torque produced by electric motors our commitment to electromobility, having put the SYSTEM has always fascinated me – how a mere necessary structures in place. Our new E-Mobility touch of the gas pedal is enough to de- d ivision combines all our existing and future electro- liver instant power, over and over again. mobility activities under one umbrella – from electric DWhen people discuss electromobility, they often for- motors and hybrid modules to power electronics. We get one thing. Not only does electric propulsion con- have brought together all the relevant expertise from serve resources – it is also really good fun. across the company, and our customers will also reap GEFAHR VORAUS These are just two of the reasons why we believe the benefits of streamlined communications and fast in electromobility – as delivered by all-electric drives, decision-making through a single point of contact. but also by hybrid and plug-in hybrid drives. These Personally, I am delighted that, as Head of Divi- two technologies in particular will hugely accelerate sion, we have been able to appoint a proven specialist FAHRERASSISTENZ the adoption of electromobility, of that we are con- with over 20 years’ experience of vehicle electronics vinced. It will be hard for the auto industry to switch and electromobility: Jörg Grotendorst. Together, we over to all-electric mobility in the space of just 10 will help develop and drive forward the electrifica- years – hybrid drives will play a key role in the tran- tion of our mobile lifestyles. Because one thing is sition. And we supply all the technologies required. certain: it will not be possible to meet the stringent LENKUNG Back in 2008, ZF was the first company in Europe emission regulations due to come into force across ZF ONBREMSEN ALL to start volume production of hybrid modules. Now Europe in 2020 without large-scale electrification. UNFALL VERMEIDEN CHANNELS ANTRIEB FAHRWERK This issue of drive isn’t the only place you’ll find ZF news. “Not only does There’s plenty more on our many digital channels. electromobility conserve resources – it’s also To follow ZF on Face- INSASSENSCHUTZbook, just scan this QR really good fun.” code using your smart- phone or mobile device. If you’d like to find out more about ZF, check out our website FAHRT SICHER at www.zf.com. In our online FORTSETZEN Dr. Stefan Sommer magazine, you’ll find videos, Chief Executive Officer of photo galleries and background ZF Friedrichshafen AG stories covering all the latest ZF a ctivities. What’s more, our DURCH high-tech company also has a presence on all the most popularINTELLIGENTE social media channels. Follow us on Facebook, LinkedIn, Twitter VERNETZUNG or YouTube and you’ll always find the most up-to-date informationMECHANISCHER UND ELEKTRONISCHER on ZF, as well as more general SYSTEME VON ZF news on mobility and technology. Erfahren Sie mehr: zf.com/technologietrends Photos: shutterstock Getty (2), Images Andreas (1), Pohlmann 3 75530_ZF_AZ_AllgMotiv_A4_DE_rz03.indd 1 08.01.16 15:39 CONTENTS CONTENTS 12 44 AT A E-POWER SPECIAL GLANCE 22 THE FUTURE IS ELECTRIC As e-mobility starts to pick up the pace, ZF is e lectrifying the street mix 27 hIDDEN CHAMPION Electric vehicles are going nowhere without s ophisticated power electronics 28 TOOLKIT FOR E-DRIVES From hybrid transmissions to axle drives: an overview of ZF’s electronic components 30 “E-Mobility IS FUN!” SAFETY DIGITIZATION Technology protects the environment – and more. Interview with Head of Division Jörg Grotendorst 12 WHERE CARS LEARN TO DRIVE 44 SILENT REVOLUTION The U.S. State of Michigan is the world center of Digitization is changing the job profiles of SH32 SOFT- OE CITY SHUFFLE automated driving. drive went to take a look engineers and IT specialists alike – even at ZF Electrically powered buses solve the noise and E pollution issues that plague inner cities 18 VISION ZERO 49 new DIRECTIONS MOBILITY From airbags to camera systems: how ZF ZF’s new think-and-do tank is developing 36 TWO TO TANGO technology is improving safety on the streets innovative business models Why ZF’s electrification strategy depends on hybrid technology and all-electric drivelines TECHNOLOGY MAGAZINE 38 TESTING ON THE TRACK 6 PROLOGUE ZF collects valuable insights for production car ZF Moment | New vehicles featuring ZF tech development on the world’s top racing circuits News from across the company 50 DRIVING GIANTS 58 YESTERDAY & TODAY Tunnel boring machines and cableways: ZF enters Front passenger airbags the market for industrial transmissions 59 SERVICE 54 CLASSY CORNERING – THE EASY WAY Masthead 22 ZF products are making motorcycle tourers safer and more comfortable than ever before RESEARCH 42 intelligent VEHICLES? Researchers at the Karlsruhe Institute of Technology are teaching vehicles to think and learn 50 32 Photos: iStockphoto, Dominik Gigler, Matthias Schmiedel, Zachary James Johnston, Felix Kästle, Illustration: ZF 4 1.2016 5 PROLOGUE_ZF MOMENT ZF at NAIAS A prominent visitor On his first visit to the North American International Auto Show (NAIAS), U.S. President Barack Obama showed great interest in the pioneering ZF t echnologies that are helping improve automotive efficiency and safety and paving the way for autonomous driving. “ZF was honored to be able to demonstrate and explain the technologies we’re using to shape the f uture of mobility to President Obama,” said Dr. Franz Kleiner, Board member responsible for North America. ZF was the only automotive s upplier at whose booth the President spent time in conversation. Bryan Johnson, Head of C ommunications North America (left), answered the President’s questions. David FreersDavid Photo: 6 1.2016 7 PROLOGUE_ZF ENGINEERING BMW 7 Series Safety Domain ECU Forward-facing camera 8-speed automatic transmission Torque converter Alfa Romeo Giulia Active Kinematics Control (AKC) Electronic parking brake 8-speed automatic transmission with torque Chassis components converter, or 6-speed manual transmission Electronic components Rear Axle Drive Seatbelt systems Vibration dampers Chassis components Seatbelt systems The cutting-edge Safety Domain ECU (SDE) is a flexible hub for control functions such as chassis and driver- The second generation of the 8HP 8-speed assist systems. The SDE comprises microcontrollers and automatic transmission delivers even greater an open software architecture into which automakers’ responsiveness, comfort and efficiency, own software modules can be integrated. reducing fuel consumption by an additional three percent. The optional stop-start function offers further potential for fuel savings. ON HIGHWAYS AND HIGH SEAS From sporty sedans through high-performance trucks to luxury yachts, these newly launched vehicles are all equipped with ZF technology. Renault Mégane Electric power steering Radar system Electronic parking brake Silver Fast yacht Chassis components Airbags ZF 7640 transmission Powered by an electric motor with very low rotational Australian boatbuilder SILVERYACHTS inertia, the electric power steering system is highly has equipped the Silver Fast with two efficient. The “power-on-demand” principle means ZF 7640 transmissions. Fitted with a the system only uses energy when it is actually MAN TGX (D38) hydraulic clutch, the transmission is s teering the vehicle, reducing fuel consumption and designed for engines capable of TraXon automatic transmission system, or Ecosplit 16-speed manual transmission CO2 emissions. The steering system is also ideal for Power take-off (PTO) modules producing up to 3,915 horsepower use with automated driving functions. ZF Intarder transmission brake (2,880 kilowatts). The lightweight Ducati Multistrada 1200 Enduro Electronic components Radar and camera system housing is very robust and impervious CDC adaptive damping system Cabin, chassis and steering components to seawater. on front fork and rear wheel Damping technology for axles and cabin The CDC adaptive damping fitted to the motorcycle’s The new MAN TGX with D38 engine is fitted with the TraXon automatic front fork and suspension struts adjusts damping force transmission system. Thanks to smart electromechanical systems and to match driving conditions in real time. This e nables Alfa Romeo, Ducati, Renault, BMW Group, enhanced functionality, TraXon offers many efficiency and productivity the system to combine the safety of hard s uspension advan tages. The modular transmission system can also be adapted to a settings with the comfort of soft settings. Photos: MAN SILVERYACHTS, wide variety of different applications. 8 1.2016 9 PROLOGUE_ZF NEWS RETRACTABLE Integrated Brake Control STEERING WHEEL Major order for brake systems Starting in 2018, ZF’s Integrated Brake Control (IBC) system will go ZF presented a raft into high-volume production in the factories of a major automaker. The system supports conventional braking safety functions as well of new technologies as semi-automated driving functions. It is compatible with all types of drivelines and helps manufacturers meet increasingly stringent at CES in Las Vegas. targets for fuel efficiency and 2CO emissions. CES in Las Vegas is the world’s largest consumer electronics trade fair. And in 2015, for the first time ever, ZF was pr esent. Under the slogan “Shaping the Next Decade of Automated Driving”, the “An organizational t echnology company demonstrated its structured response to the prevailing masterstroke.” New giant transmission for offshore wind turbines megatrend: autonomous driving. In a That’s how renowned German legal publishing house concept car developed by Swiss firm Maximizing power output Juve described ZF’s acquisitions of TRW Automotive and Rinspeed, ZF also introduced an Bosch Rexroth’s industrial transmissions business. innovative steering wheel with hands ZF is vastly expanding its wind power business.