Into the Future –

With e-Mobility
ZF PRODUCTS FOR HYBRID
AND ELECTRIC VEHICLES
 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 suc-
cessfully walk the challenging line between
the need to shape individual mobility while
also doing everything possible to preserve
the environment and resources. It is impos-
Contents
sible to imagine automobiles of the future
Electric mobility –
a megatrend with potential
page 4 without ZF driveline technology because,
Diversity in efficiency:
electrification of the driveline
page 6 with its modern and reliable components,
New features thanks to e-mobility page 8 ZF is also paving the way for many trends,
Electric Motor

Hybrid module
page 10

page 11
such as electrification of the driveline. This
Hybrid Transmission page 12 culture of innovation as well as the abil-
48V Hybrid system

Power Unit
page 13

page 14
ity to produce components of the highest
Electric vehilce drive page 15 quality has made ZF a valuable partner in
ELECTRIC TWIST BEAM AXLE

Modular electric rear axle concept

page 16

page 17
the international automotive industry.
The ZF Group page 18

Research and development page 19

To secure mobility

2 3
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 experi-
mented 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 avail-
able 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 “emerg-
ing 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: Hy-
brid electric vehicles combine the advantages of electric
4 5
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 electric-
ity their overall carbon footprint will improve consider-
ably. 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 hydro-
gen or methanol stored in tanks.
ZF: Solutions from a single source
In the context of this electrification megatrend, automo-
tive 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 par- larly efficient. Customers who buy electric drive systems
allel hybrid concepts. The product portfolio ranges from from ZF benefit from the Group’s overall expertise. After
integrated 48V solutions with 15 kW which can be used all, ZF has valuable system know-how about the entire
in mild hybrid systems and already offer a large number driveline, including its functional and structural inte-
of advantages of electric drives to powerful electric mo- gration into the automobile. The Group’s expertise in
tors with up to 120 kW for plug-in hybrid transmissions. the area of mechanics derived from its well-established
Automotive manufacturers appreciate ZF’s expertise in driveline technology product portfolio is equally valu-
offering complete hybrid modules in which the electric able to ZF customers. It includes topics as complex as the
motor, a separating clutch, and torsional dampers which damping of torsional engine vibrations or efficient torque
balance out rotational irregularities of the combustion transmission.
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 auto-
matic 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 particu-
Diversity in efficiency:
electrification of the driveline overview of electrified drive configurations

HEV – Hybrid Electric Vehicles EV – Electric Vehicles

Nowadays, e-mobility covers a very broad range of

drive system types for which ZF is optimally prepared
today and in the future.

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

More cost-effectiveness and less or no emissions: This serial hybrid drives are integrated according to a differ-
is the objective when it comes to implementing almost ent model: In most cases, the combustion engine drives a
all electrified passenger car drives. This goal can be generator which supplies energy for one or more electric
achieved in different ways. motors for the axle or wheel drive.

Fuel Cell
Twice as powerful Simply great
In hybrid electric vehicles or HEV, the conventional Finally, in pure electric vehicles or EV, no combustion
combustion engine is supported by at least one electric engine is installed at all. The energy for the electric
motor. Its respective capacity can be used for an initial motor or motors is either supplied by a battery, as is the
classification: A micro hybrid can, for example, switch off case for battery electric vehicles or BEV; or a fuel cell on
the combustion engine in a stationary vehicle (start/stop) board generates the electric energy by means of a chemi-
as well as recuperate braking energy to a limited extent cal reaction, as is the case for fuel-cell vehicles (fuel cell Full hybrid Mild hybrid, parallel Serial hybrid Fuel-cell (electric) vehicle
front-transverse drive front-transverse drive or range extender
but does not actively drive the vehicle. The latter is pos- (electric) vehicle – FC(E)V). ZF works intensively on elec- with electric motor 48 V or high voltage
sible starting with the mild hybrid in which an electric tric vehicle innovations, particularly with its complete electric 4-wheel drive
motor for instance complements the gasoline or diesel electric axle drive systems.
engine via the boost mode; it can, however, not drive
the car independently. This is possible in the full hybrid Cost-effective at 48 V Overview of hybrid categories
which, as a plug-in hybrid electric vehicle (PHEV), can A more powerful on-board supply system in passenger
also be charged using any power outlet. It already tackles cars had already been a topic in the automotive industry Hybrid categories Micro Mild 48V Full (HEV) Plug-in (PHEV)
many everyday challenges purely electrically: A PHEV before hybrid vehicles were introduced: After all, elec-
equipped with the ZF plug-in hybrid transmission even trics and electronics mean more and more consumers Main functions Start/stop Start/stop Start/stop Start/stop
(Boost mode) Boost mode Boost mode Boost mode
reaches speeds of up to 120 km/h and a range of up to 50 in the passenger car, taxing the classical 12 V network (Recuperation) Recuperation Recuperation Recuperation
kilometers without generating any local emissions. to the limits of its capacity. An additional 48 V on-board (Electric maneuvering) Limited electric driving Electric driving
supply system is also a less costly step toward hybridiza- Sailing Sailing

As an alternative, HEVs can also be categorized based on
the interplay between the conventional combustion en-
gine 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
tion. A mild hybrid system based on 48 Volts already Max. performance level 3-5 kW 10 -15 kW 20-50 kW 75-120 kW
makes a large number of hybrid functions possible – sail-
ing, 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.

6 7
New features
thanks to e-mobility
Hybrid or pure electric drives offer a number of functions
which make driving more efficient.
Start/stop
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.
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.
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
to be smaller and more fuel-efficient in hybrid vehicles –
keyword: downsizing.
8 9
Functions of the hybrid system
Start/stop
The electric drive starts the combustion engine
and stops it comfortably if required.
Recuperation
Braking energy is converted into electric energy.
Boost mode
While starting or accelerating, the torque of the
combustion engine is increased by the additional
torque of the electric motor.
Electric driving / electric maneuvering
The electric drive unit drives the vehicle
Electric driving independently.
As soon as electric motors drive the passenger car inde-
pendently, 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 common.
Sailing
Electric maneuvering Switching off and decoupling the combustion engine
Combustion engine vehicles consume a lot of fuel when while driving, for instance when letting the vehicle coast
to a stop. If required, the engine is switched on again by
starting from a standstill or maneuvering at walking a tap on the accelerator pedal.
speed. When the electric motor takes over this task, the
vehicles use considerably less fuel.
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.
ELECTRIC MOTOR HYBRID MODULE

PRODUCT DETAILS ELECTRIC DRIVES PRODUCT DETAILS ELECTRIC DRIVES

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

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

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

Electric motor
Rotor position sensor

Separating clutch
Electric motor

Interface to transmission
Torsional vibration damper

Torsional vibration damper

Interface to transmission

Interface to combustion engine Interface to combustion engine

Housing

Housing

Separating clutch
actuation

10 11
HYBRID TRANSMISSION 48V HYBRID SYSTEM

PRODUCT DETAILS ELECTRIC DRIVES PRODUCT DETAILS ELECTRIC DRIVES

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

Type IL269-70 Type IL292-51

Outer diameter 269 mm Outer diameter 292 mm

Active length 70 mm Active length 51 mm

Axial length module approx. 150 mm Axial length module approx. 145 mm

Voltage range 220 – 420 Vdc Voltage range 36 – 52 Vdc

Max. power 90 kW Max. power 15 kW

Max. torque 250 Nm Max. torque 200 Nm

Max. speed 7,000 rpm Full hybrid, parallel Max. speed 7,000 rpm Mild hybrid, parallel Mild hybrid, parallel
rear-wheel drive front-transverse drive rear-wheel drive
48 V or high voltage 48 V or high voltage
Max. torque separating element (optional) 800 Nm

Consisting of Consisting of
Electric motor Electric motor
Torsional vibration damper Power unit incl. rotor position sensor
Separating clutch Separating clutch Housing
Housing Optional: torsional vibration damper
Optional: separating element

Interface to transmission
Housing

Interface to optional
Interface to
torsional vibration damper Electric motor
combustion engine

Torsional vibration damper

Housing
Electric motor Power unit incl. rotor position sensor

12 13
POWER UNIT ELECTRIC VEHICLE DRIVE

PRODUCT DETAILS PRODUCT DETAILS ELECTRIC DRIVES

Specification Power unit Unit Drive configuration Specification Asynchronous machine (ASM) Unit Drive configuration

Type PUM Type eVD2

Volume 8 l Dimensions incl. housing 450 x 510 x 380 mm

Max. voltage 440 Vdc Active length 150 mm

Max. current 510 Arms Axial length module approx. 450 mm

Fuel Cell

Continuous current 240 Arms Voltage range 220 – 420 Vdc

Safety level C ASIL Max. power 150 kW

Fuel Cell

Max. speed 7,000 rpm Max. torque at axle 3,500 Nm

Max. speed 13,000 rpm Full hybrid Battery electric vehicle Fuel-cell (electric) vehicle
front-transverse drive
with electric motor
electric 4-wheel drive

Consisting of
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

Differential

14 15
ELECTRIC TWIST BEAM AXLE Modular electric
rear axle concept
PRODUCT DETAILS ELECTRIC DRIVES An electric drive system integrated into the axle PRODUCT DETAILS
According to the customers, supplying driveline and
Specification Permanent-field synchronous machine (PSM) Unit Drive configuration chassis technology from a single source has always been Drive configuration
ZF‘s strength. This advantage also remains in times
Type eTB of e-mobility. For instance, ZF offers the electric drive
Dimensions incl. damper approx. 595 x 1500 x 250 (560) mm integrated into a complete axle system. For ZF customers,
and top mount this considerably reduces development costs because
Active length 90 mm ZF handles the coordination of internal interfaces.
Fuel Cell Fuel Cell
Voltage range 220 – 420 Vdc
ZF develops, fine-tunes, and tests the axle including
Max. power 75 kW
the electric drive, in accordance with the requirement
Max. torque at axle 1,400 Nm specification. In the process, different axle types can be
Max. speed 21,000 rpm used depending on the application. For this purpose, ZF
Full hybrid Battery electric vehicle Fuel-cell (electric) vehicle Full hybrid Battery electric vehicle Fuel-cell (electric) vehicle
front-transverse drive provides a modular rear axle concept which is based on front-transverse drive
with electric motor with electric motor
electric 4-wheel drive essential customer requirements. Since ZF can imple- electric 4-wheel drive

ment its experience with passenger car axle systems in

the process, the electric drive is integrated seamlessly
Consisting of and according to the requirements.
Electric motor
Two-stage spur gear drive
Aluminum housing
Integrated mounting
of damper & spring
Twist-beam axle

16 17
The ZF Group Research and development to
secure mobility

Innovations are not an end in themselves, they must pay off: For manufactur-
ers, fleet owners, and drivers, but also for the environment and society. Each
new development must prove itself among the conflicting priorities of these
criteria.

Shaping the future responsibly

Our enthusiasm for innovative products and processes and our uncompromising pursuit of quality have made The ZF Group draws upon an international network of
us a global leader in driveline and chassis as well as active and passive safety technology. We are contributing development centers. Each year, ZF invests approxi-
towards a sustainable future by producing advanced technology solutions with the goal of improving mobility, mately five percent of its sales in R&D. With success,
increasing the efficiency of our products and systems, and conserving resources. because innovative products from ZF set the standards
for state-of-the-art technology – again and again.
Our customers in the automotive and industrial sectors welcome our systematic orientation towards products
and services which provide great customer value. Improvements in energy efficiency, cost-effectiveness, dynam- Development work at ZF is organized according to
ics, safety, and comfort are key to our work. Simultaneously, we are aiming for continuous improvement in our decentralized and corporate functions. The divisions
business processes and the services we provide.As a globally active company, we react quickly and flexibly to and business units focus on markets and product exper-
changing regional market demands with the goal of always providing a competitive price/performance ratio. tise, ensuring customer-centered, competitive techno-
logical product development. Corporate R&D works
Our independence and financial security form the basis of our long-term business success. Our profitability with a strong emphasis on basic research and theory,
enables us to make the necessary investments in new products, technologies, and markets and we thus secure and supports the operational development departments
the future of our company on behalf of our customers, market affiliates, employees, and ZF owners. in the divisions.
Our tradition and values strengthen our managerial decisions. Together, they are both an obligation and an Groundbreaking innovations
incentive to maintain a reliable and respectful relationship with customers, market affiliates, and employees. Over the past years, this partnership has produced
Our worldwide compliance organization ensures that locally applicable laws and regulations are adhered to. product innovations that have since become bench-
We accept our responsibility towards society and will protect the environment at all of our locations. marks in the industry: Just some examples are the
8-speed automatic transmission for cars as well as
Our employees worldwide recognize us as a fair employer, focusing on the future and offering attractive career hybrid transmissions and hybrid management for
prospects. We value the varied cultural backgrounds of our employees, their competencies, and their diligence cars and commercial vehicles, or the modular TraXon
and motivation. Their goal-oriented dedication to ZF, beyond the borders of their own field of work and location, transmission system for commercial vehicles. Ground-
shapes our company culture and is the key to our success. breaking innovations from ZF are in use today not just
in passenger cars and commercial vehicles on the road,
but also in all kinds of craft on the water and in the air.
What‘s more, the innovative power of ZF is set to
increase in the future. Proof of this is already provided
by the number of patents pending: A look at the statistics
of the German Patent and Trademark Register shows that
ZF is among the top ten applicants for patents – at eye
level with many large automotive manufacturers. Each
year, the research departments successfully complete
more than 10 000 projects, covering the full range from
basic research to product applications. This high project
volume is necessary to ensure mobility in the future. The
trend toward hybrid solutions already shows that green
drive technology is very complex. The same goes for pure
electric drives and lightweight design engineering. Cur-
rently, ZF engineers are conducting pioneering work on
alternative materials, broader approaches in design and
testing, and new production processes.

18 19
ZF Friedrichshafen AG twitter.com/zf_group
Ernst-Sachs-Strasse 62 facebook.com/zffriedrichshafen
youtube.com/zffriedrichshafenag
D-97424 Schweinfurt
Germany
Phone +49 9721 98-0
Fax +49 9721 98-2290
www.zf.com

© ZF Friedrichshafen AG - E-Mobility Cars Electric Drive Technology - 09/2015 (EN20150831)