German automotive specialist ZF has developed a range of game-changing technologies that promise to significantly improve the performance and efficiency of electric vehicles (EVs). These technologies include high-efficiency motors, reduction gearboxes, and intelligent suspension systems. ZF’s innovations are set to debut in the highly anticipated Lotus Eletre, but they also have broader implications for the future of the automotive industry as it shifts away from traditional combustion engines.
One of ZF’s most notable advancements is the EVSys800 motor, which sets a new benchmark for torque density. With a torque density of 70Nm/kg, the motor is 30% more efficient than existing designs. Despite its lightweight and compact design, weighing only 80kg, the EVSys800 motor boasts a peak rated power of 300kW (402bhp). This impressive power output is achieved through the use of all-alloy casings and braided winding, which eliminates 200 laser welds, reduces package size by 10%, and increases power by 50%.
To ensure optimal performance, ZF has also developed a new thermal management system with direct conductor cooling. This system keeps the stator cool and utilizes waste heat to power ZF’s TherMas heat pump. As a result, the EVSys800 motor can run for prolonged periods at 75% of its peak power output, equating to 302bhp in the Lotus Eletre. In comparison, a typical motor rated at 268bhp might only be able to sustain 101bhp continuously. This improved cooling capability not only enhances performance but also increases overall efficiency.
In addition to the high-efficiency motors, ZF has also introduced a new planetary-gear co-axial reduction drive. This innovative design incorporates both motor-reduction and differential functions, resulting in a quiet and efficient drivetrain. The reduction drive features acoustic-optimized gear designs that minimize noise and vibration, providing a smooth and comfortable driving experience.
ZF’s advancements extend beyond powertrain technologies. The company has also developed an intelligent suspension system that integrates with the electric motor and its drive components. This system, controlled by ZF’s Cubix software, aims to deliver high-quality road dynamics and enhance overall vehicle performance. Cubix acts as an on-board supercomputer, capable of liquid-cooling and up to 1500 tetra operations per second (TOPS). It controls intelligent dampers, steer-by-wire hardware, brake-by-wire components, and integrates seamlessly with the e-motor drive controller.
ZF’s game-changing technologies have the potential to revolutionize the automotive industry. The Easy Turn multi-link front axle, for example, offers more than 80 degrees of steering angle, significantly improving maneuverability. Combined with rear-wheel steering, this technology reduces the turning circle and allows vehicles to pivot around the rear wheels, enhancing overall agility.
Another notable innovation is the Smart Chassis Sensor, which measures the precise deflection of the front wheel. This sensor captures detailed information about road conditions, such as potholes and rough surfaces, and provides advanced warning to drivers. This data can be overlaid on sat-nav maps, allowing drivers to choose smoother routes and avoid rough roads.
ZF has also introduced Heatbelt technology, which uses high-resistance wires woven into seatbelt fabric to provide instant warming effects for occupants. This technology reduces the demand on HVAC systems and can be particularly beneficial in electric vehicles, where it helps to minimize parasitic drain on the battery.
Furthermore, ZF’s TherMas BEV HVAC System utilizes waste heat from the battery to power a compact and efficient heat pump. With a coefficient performance twice that of existing pumps, TherMas offers improved heating capabilities while reducing weight and energy consumption.
Lastly, ZF has incorporated advanced passive safety technology into its seatbelt systems. These systems feature a more powerful motorized belt retractor, capable of haptic warnings and adjusting for out-of-position occupants. The seatbelt systems also include features such as rhythmic jiggling to wake up drowsy drivers and powerful jerks to reposition occupants during heavy braking or airbag deployment.
ZF’s advancements in high-efficiency motors, reduction gearboxes, and intelligent suspension systems are set to transform the performance and efficiency of electric vehicles. With these technologies, ZF is paving the way for a new era of electric mobility, offering improved power, range, and overall driving experience. As the automotive industry continues to evolve, ZF’s innovations will play a crucial role in shaping the future of electric vehicles.