Charts ZF Workshop Valencia 2012

Innovative Products from ZF
E-Mobility - Efficieny - Performance
ZF-Technik Workshop
Valencia, 22.-24. Okt. 2012
Dr. Hans-Jörg Domian
© ZF Friedrichshafen AG, 2012

ZF Friedrichshafen AG
Topics
Efficiency
Product Strategy Econnect

E-Mobility Performance
Electric Drive Intelligent Wheel Dynamics
OTA 2 Innovative Technik von ZF - Valencia 12-10-22

Topics


ZF – Technological Leadership
Systems Partner With Complete Vehicle Expertise
Partial Functionality
Vehicle Network
Modules / Transmission
Systems System
Axle System
Units Transmissions Steering System
Chassis
Starting Components
Components

Components

Global Megatrends
Demographic
Globalization
Change

New
Urbanization Mobility
Ecology

Optimization of Conventional
Powertrain
Reduction of Energy Consumption and Emissions

9 HP
Power
Traffic / Transport / Mobility
Generation
Optimization
Lightweight Alternative
Conventional Hybrid Drive Electric Drive
Design Energy
Powertrain
cPower 8 HP

Hybrid Drives
Power
Generation
Optimization
Design Energy
Powertrain
8 P 70 H
3rd Generation
AVE130 EcoLife Hybrid

Electric Drives / Alternative Energy

eTB
Power
Generation
Optimization
Design Energy
Powertrain
RW1 EVD1

Lightweight Design

Rear axle concept with wheel guide
Power
Generation
GRP transverse (leaf) spring
Optimization
Design Energy
Powertrain
Brake Module Plastics suspension strut

Plastics damper top mount
Plastics pneumatic spring
Plastics wheel carrier

Topics


The Disconnect Idea
In-line 4WD-driveline
Benefits by 4WD
• increased traction
• improved handling and safety
• improved drivetrain response
Disadvantages by 4WD
• package space and integration East-West 4WD-driveline
• added weight
• increased fuel consumption
and CO2 emission

Improving fuel consumption by temporarily disconnection of 4WD components

ZF-Demonstrator for ECOnnect
CO2-reduction up to 3-5% at full AWD-performance

when AWD is not needed, its losses are switched off
RDU PTO
„twin clutch system“
(without differential) Ring Gear disconnect
by dog clutch
Functionalities:
• Torque distribution Functionalities:
on demand • bring rear driveline
• Torque Vectoring to stand still
• Traction
improvement RDU and PTO as implemented in ZF demo vehicle
(Land Rover Freelander)
Almost complete disconnect of rear driveline,

Proven drag torque reduction up to 93% (related to standard units)!
strategy-based, fast and imperceptible changeover between 2WD/AWD

Driver has full AWD-performance in all relevant driving situations
OTA 12
ZF ECOnnect
PTO
• separated input shaft by dog clutch
• elektromechanic actuation
ECOnnect
RDU – Sport
• twin clutch system (without differential)
• Locking- and Torque Vector-Functionality
• 2 elektromechanic actors
RDU - Basic
Option for
• AWD-clutch on one output shaft
basic version • used for active torque distribution and AWD-disconnect

OTA 13
Connecting sequence of ZF ECOnnect
1. 2. 3.
Synchronize Engage Build up of
propshaft dog ring rear axle torque
PTO
50 ms 40 ms
to to 100ms
100 ms 70 ms
RDU
190 – 270 ms

E-Motor position controlled connection sequence
Fast, reliable and silent activation process under all driving conditions

Performance of traction
Improvement by individual torque transfer
Hang-on AWD Twin clutch AWD
low mue
low mue
• limited traction • increased torque on µ-high

• brake intervention required • smooth and relaxed operation

full locking capabilities in longitudinal and transversal direction
Improved traction and gradability even under severe slip conditions

Simulation of CO2 saving
Ptotal losses = Pdrag torque + Pgear efficiency
- 4.7%
- 5.3% - 2.3% total saving
CO2 emission [g/km]
-4.2% -2.3% -3.9% drag related saving
• NEDC cycle
• mid-sized SUV
• gasoline engine

Simulation derives a pure drag torque related saving potential of -5.3% CO²
The ZF-Disconnect System achieves an overall reduction of -4.7% CO2
Topics


Motivation iWD

iWD
Improved Safety and Driving Dynamics
optimization of tire forces by active systems
Wheel position control

Target Setting
stability intervention improved agility
definition vehicle characteristic improved traction
driving stability
yaw yaw
torque torque
brake driving safety

intervention

comfort

Target Setting
agility
yaw torque
safety
fuel
consumption

critical
tire/road contact

Target Setting
improved traction regarding straight driving and cornering!
driving stability
driving safety
traction

iWD

iWD
Improved Safety and Driving dynamics

AKC® (Active Kinematic Control)
Control Arm with adjustable Length
technical data
320 W mechanical,
approx. 500 W electrical
range: ±18 mm (±6°at wheel)
dynamics: 60 mm/s
max. force: 4 kN
holding force during misuse: 17 kN
weight under 3 kg
size: 212x85x120 mm
low unsprung mass by compact design
4
design
electric motor 2
gear box 3
1

fail-safe lock
ball-type linear drive
iWD

Torque Vectoring Axle Drive
“Vector Drive”
input
“brake“
planetary
gear
torque vector unit
torque vector unit

differential
Concept Vehicle with interacting Systems
AWD Vector Drive AS ERC AKC

Influence on Self-Steering Characteristics
steady-state circular test *

2004 im Kurzprofil
90
Lenkradwinkel [°]
conventional
influence Active Steering 80 Active Steering AS
Torque Vectoring TV
• agility at low vveh
interaction AS & TV
• comfort at high vveh 70
60
influence Torque Vectoring 50

• gets higher with rising vveh
40
• optimized tire force
distribution 30
adjustable range
20
influence interaction
10
self-steering char. 0 1 2 3 4 5 6 7 8 9 10

adjustable in all areas lateral acceleration [m/s2]
0 51 72 88 102 114
velocity vveh [km/h]
* Radius 100m, Versuchsstrecke Nardo (Februar 2007)

Topics


Driveline Electrification
Terms, Classes, Functions, Steps
(Micro Mild Hybrid Full Hybrid parallel

Plug-In-Hybrid Electric Vehicle
Hybrid) parallel (serial, power split)
Range Extension
ICE Driving Pure

Electric Driving
Electric Driving
(with
Electric Driving external energy)
Regeneration/ Electric (regen energy)
Stop/Start Boosting Launch
Step 0 Step 1 Step 2

Electric driving speeds
– small medium all
ICE driving speeds

all – / some

Driveline integrated Hybrid
One package: Torque converter, Hybrid module
8HP70 8P70H

Electric Drive Designed by ZF
Base vehicle and design data
Design weight (incl. driver and partial load) 1.250 kg
Axle torque 1.400 Nm
Axle power (maximum during acceleration) 90 kW
Gradeability 35 %
Maximum speed (equivalent power: 30 kW) 150 km/h
Acceleration 0-100 km/h < 10 s

Motor technology and speed
considerations
60
ASM
50
Motor weight [kg]
40
Design focus
30
PSM
20
10
Equivalent motor speed at 150 km/h [rpm]:
8.000 13.000 21.000 26.000 40.000
0
6 10 16 20 30

Final eDrive ratio i (–)
Effect: light-weight and compact solution due to high speed approach
ZF’s EVD1 for Small Passenger Cars
Specifications:
Performance:
max. 90 kW / 30 kW cont.
Axle torque:
approx. 1.400 Nm
Max. Speed: 21.000 rpm
Characteristics:
Single-speed two-step
transmission: i = 16
Compact, light weight: 45 kg
Power density: 2,0 kW/kg 460 x 325 x 250 mm
Optimized acoustics

Scaleable up to:
130 kW / 2.000 Nm axle torque

Testing Vehicle for EVD1

EVD1 Testing Vehicle
ZF Stromos with EVD1
E-Vehicle based on
Suzuki Splash / Opel Agila
Replacement of the existing E-drive by
E-drive EVD1 and ZF inverter
Concept proof – driving functions

Driveline test under real conditions
Evaluation of acoustic behavior
Vehicle testing started

Available for demonstration
purposes since August 2012

EVD1
Acoustics
MBS Model
Vehicle tests Bench tests
Gear layout optimized towards

high speed concept
Latest methods and tools used to
understand and improve the acoustic
behavior
No driveline noise perceptible in or

outside the demo vehicle
FE Model

EVD1 – Outlook
Integration levels for central electric drive
Cooler
Axle drive
E-Motor
electronics
Integration
Power
Level 1
CAN Transmission
Integration
Level 2
Battery

Progress will be made by overall system optimization and integration
Summary
Pure electric driving technologies will co-exist with conventional

and hybrid solutions for a long time
E-mobility solutions will have to fulfill various specifications within a
small range of design kit variants
The use of e-axle drives for both EV and Axle based HEVs
is reasonable
System optimization has to be applied to E-motor,
gears and inverter in a holistic approach
“Power out of speed” is a feasible
approach regarding the key factors
of an EV drive system
Integration is a key factor

for optimized solutions

Thank you very much for your attention!


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Innovative Products from ZF

E-Mobility - Efficieny - Performance

Dr. Hans-Jörg Domian

© ZF Friedrichshafen AG, 2012

© ZF Friedrichshafen AG, 2012

OTA 2 Innovative Technik von ZF - Valencia 12-10-22

Product Strategy Econnect

© ZF Friedrichshafen AG, 2012

OTA 3 Innovative Technik von ZF - Valencia 12-10-22

Units Transmissions Steering System

© ZF Friedrichshafen AG, 2012

OTA 4 Innovative Technik von ZF - Valencia 12-10-22

© ZF Friedrichshafen AG, 2012

OTA 5 Innovative Technik von ZF - Valencia 12-10-22

Reduction of Energy Consumption and Emissions

© ZF Friedrichshafen AG, 2012

Reduction of Energy Consumption and Emissions

© ZF Friedrichshafen AG, 2012

Reduction of Energy Consumption and Emissions

© ZF Friedrichshafen AG, 2012

Reduction of Energy Consumption and Emissions

Brake Module Plastics suspension strut

© ZF Friedrichshafen AG, 2012

Product Strategy Econnect

© ZF Friedrichshafen AG, 2012

OTA 10 Innovative Technik von ZF - Valencia 12-10-22

© ZF Friedrichshafen AG, 2012

OTA 11 Innovative Technik von ZF - Valencia 12-10-22

CO2-reduction up to 3-5% at full AWD-performance

Almost complete disconnect of rear driveline,

© ZF Friedrichshafen AG, 2012

© ZF Friedrichshafen AG, 2012

© ZF Friedrichshafen AG, 2012

OTA 14 Innovative Technik von ZF - Valencia 12-10-22

• limited traction • increased torque on µ-high

© ZF Friedrichshafen AG, 2012

OTA 15 Innovative Technik von ZF - Valencia 12-10-22

Ptotal losses = Pdrag torque + Pgear efficiency

-4.2% -2.3% -3.9% drag related saving

© ZF Friedrichshafen AG, 2012

Product Strategy Econnect

© ZF Friedrichshafen AG, 2012

OTA 17 Innovative Technik von ZF - Valencia 12-10-22

© ZF Friedrichshafen AG, 2012

Wheel position control

© ZF Friedrichshafen AG, 2012

stability intervention improved agility

definition vehicle characteristic improved traction

brake driving safety

© ZF Friedrichshafen AG, 2012

OTA 20 Innovative Technik von ZF - Valencia 12-10-22

stability intervention improved agility

definition vehicle characteristic improved traction

© ZF Friedrichshafen AG, 2012

OTA 21 Innovative Technik von ZF - Valencia 12-10-22

stability intervention improved agility

definition vehicle characteristic improved traction

improved traction regarding straight driving and cornering!

© ZF Friedrichshafen AG, 2012

Wheel position control

© ZF Friedrichshafen AG, 2012

optimization of tire forces by active systems

Wheel position control

© ZF Friedrichshafen AG, 2012

Gear layout optimized towards