Renowned Tier One supplier ZF recently exhibited the EVBeat concept car at the company’s Global Technology Day in Friedrichshafen.
What’s interesting about the event was the integration of the new EVSys800, ZF’s modular 800-volt drive unit designed specifically for electric cars.
“Sustainable mobility is at the core of our corporate strategy. Based on an extremely efficient production vehicle, we are showing the potential that future electric drive components offer when we combine them into an even more efficient overall system.”
Stephan von Schuckmann, ZF Board of Management member responsible for electrified driveline systems
About the EVSys800
Efficiency and power
ZF’s EVSys800 is a modular 800-volt drive unit that combines silicon carbide power electronics with an electric motor and a reduction gearbox.
Apart from that, the 800-volt drive unit also offers impressive torque capabilities and reduced weight. It is 40 kilograms (88 lb) less than the company’s model. In effect, the new drive unit offers a lighter powertrain that increases passenger and cargo capacity.
In addition, it is 50 mm narrower than its predecessor, owing to its more compact reduction gearbox. It also has ZF’s patented “Braided Winding” technology in the electric motor’s construction.
More remarkably, the EVSys800 has a 206 kW continuous power rating and a 275 kW peak power output, enabling the unit to deliver unprecedented performance. It also boasts a maximum torque of up to 70 Newton meters per kilogram of weight, enabling more than 5000 Newton meters of torque at the drive axle.
Cooling innovations
ZF equipped the EVSys800 with an advanced cooling system to address heat-related concerns in high-power operation in electric cars.
The company guaranteed the EVSys800’s effective heat dissipation without substantial size and weight changes. The company directed the cooling oil flow around the copper rods inside the motor to achieve that.
In addition, ZF developed the “Braided Winding” tech to lessen the space necessary inside the motor housing by 10%. It also improved the inverter and other essential components to enhance the drive unit’s efficiency.
“Our goal was to make this drive as compact and lightweight as possible while maintaining high driving dynamics and increasing efficiency in real-world operation.
In terms of torque density, we are at the top of the podium when we compare ourselves with e-drives for passenger cars currently available on the market. At the same time, we paid strong attention to the sustainability aspect during development. With this system, we can perfectly meet the main requirements of our customers — namely efficiency, performance and costs.”
Dr. Otmar Scharrer, ZF’s Head of Development for Electric Driveline Systems
The innovations continue, as ZF has also developed a new heating and cooling system called TherMaS.
About the TherMaS
In addition to the EVSys800, ZF has introduced an integrated heating and cooling system, “TherMaS.” This system utilizes an 800-volt heat pump that employs propane as the refrigerant.
The propane integration is undoubtedly strategic, as propane heat pumps are highly efficient. It can also substantially enhance range during cold weather operations.
TherMaS controls the temperature of the electric motor, power electronics, and charging parts. Remarkably, it only employs 50% of the refrigerant amount used by conventional heat pumps. Still, it can deliver twice as much cooling power.
Improved connectivity
ZF has also invented its own powertrain software, which integrates all vehicle systems into the ZF cloud.
The company claims that this innovative software can predict optimal operating temperatures for electric cars per driving profiles or individual drivers, preparing the system accordingly.
Apart from that, the electronic assistance system gives drivers real-time advice on efficient vehicle usage. It includes optimized acceleration, deceleration, and maximum speed. Such guidance enables accurate range calculation before going on the road.
See Also:
· Wolfspeed, ZF partner to build a new German EV chip factory and R&D center worth $3bln
· NIO and ZF to collaborate on steer-by-wire, a technology key to autonomous driving
· Ford announces additional investment in Halewood to build 420,000 EV drive units per year
· Hyundai signs deal with Vitesco for electric drive units for smaller cars
· Tesla addresses inconvenience of left-hand drive models in the UK with ‘The Reacher’
ZF expects to launch the initial production models of the EVSys800 in 2026. This innovative technology can undoubtedly enhance the performance of electric vehicle owners.
