ZF rolls out new e-drives for light commercial vehicles

ZF is already expanding its comprehensive product range for pure e-drives to include the functions that customers and end users want.

The latest generation of electric drives for light commercial vehicles has been announced by ZF. These include the drives' compact design, the 'discrete approach' in power electronics, and the resource-saving use of materials, which also makes the drives' production more sustainable. The new ZF e-drives, with their modular concept, assist automotive manufacturers in customizing the further electrification of their entire model range.

The new generation of ZF e-drives will be available as a complete system on the market in 2025, with individual components going into series production earlier. ZF claims that its new high-voltage converter has a 99.6 percent efficiency. The new technologies will offer higher efficiency, more power, and shorter charging times to end users.

Approach to capture emerging EV trends

ZF is already expanding its comprehensive product range for pure e-drives to include the functions that customers and end users want. To better and more quickly meet the highly diverse market demand, the Technology Group is now introducing a new generation of electric drives based on a modular overall concept that includes an electric motor, inverter, transmission, and software.

ZF is focusing on three basic systems that will meet customers' main requirements, namely efficiency, performance, and cost. ZF is consistently advancing the strategy of developing sustainable and efficient mobility for the future with the next generation of electric drives.

ZF offers fully integrated electric drive systems with its new generation of e-drives. With its high level of interface expertise and unique know-how for driving strategies, its application engineers can fully meet customer requirements. However, the Group will also sell the innovative components that form the foundation of its own system solution separately.

Power electronics use 'discrete package technology' to strike a balance between component uniformity and adaptability. Individualization occurs at the chip level: Individual power semiconductor switches are used to construct a discretely structured ZF inverter. This modularity allows for greater performance scalability than complex power modules. Furthermore, ZF's 'discrete package technology' necessitates fewer types of components than conventional power modules.

When compared to current market technology, the new, highly integrated e-motor increases power density. A new cooling concept and winding technology are crucial in this case. Oil can now flow directly around the copper rods, precisely where the most heat is generated during operation, thanks to the new cooling concept.

ZF's new e-motor features innovative cooling concepts and winding technology. With the same weight and installation space, such highly efficient cooling significantly improves performance. The electric motor's continuous power is increased to up to 85 percent of its peak power. Furthermore, the use of heavy rare earth can be greatly reduced, allowing the e-motor to be produced in a more environmentally friendly manner.

ZF has transferred its world-leading planetary gearbox know-how to the next generation of electric drives with its new coaxial reduction gearbox. Not only do two integrated planetary gears generate the desired axle ratio, but they also include a fully integrated differential function.

When compared to traditional offset concepts, the new solution saves weight and installation space without sacrificing efficiency, noise, or vibration.

High-voltage converters (DC-DC converters) are important components of fuel cell-powered electric drives. They compensate for the fuel cells' low output voltage and significant voltage drop at high loads. The new high-voltage converter from the ZF power electronics platform, designed for passenger car and commercial vehicle applications, has an efficiency rating of 99.6%.

About ZF

ZF is a global technology company that manufactures systems for passenger cars, commercial vehicles, and industrial applications.

With its extensive product portfolio, the company provides integrated transportation and mobility solutions to established vehicle manufacturers, mobility providers, and startup companies. As ZF transitions to a software and cloud-based company, digital networking and automation are focal points of system development. ZF enables vehicles to see, think, and act.

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