Main provider ZF has launched an idea car primarily based on the Porsche Taycan, made to indicate off the next-generation EV drivetrain it’s going to promote to carmakers from 2026.
The corporate – finest recognized for its computerized transmissions – claims its EVbeat idea units requirements for compactness, light-weight design, and power effectivity. That’s vital as a result of placing greater batteries into long-range electrical vehicles is hardly an environment friendly tactic so as to add vary.
ZF’s ‘EVSys800’ drive system contains an 800V electrical structure to permit fast DC charging, however provides new silicon carbide energy electronics, and a newly developed e-motor and discount gearbox. Energy from the motor is 275kW peak, or 206kW steady.
This drive system sans battery weighs 74kg, which is 40kg lighter than ZF’s present 800V sequence drive system when making the identical outputs, the corporate says.
A newly patented type of electrical motor winding saves house and cuts copper use, serving to minimise value, and there’s a brand new cooling technique – oil flows straight across the copper rods – that doubtlessly permits extra efficiency in a smaller set up house.
In the meantime the inverter has been “essentially redesigned” as effectively, with ZF claiming “vital enhancements” to issues like electromagnetic compatibility, and the packaging of energy modules and capacitors.
A brand new coaxial discount gearbox transmits motor drive through two planetary gear units that generate the specified last drive ratio, and carry out an built-in differential perform. This makes the off-the-shelf product simpler to package deal, ZF claims.
“With this method, we are able to completely meet the principle necessities of our clients – particularly effectivity, efficiency and prices,” stated ZF head of growth for electrical driveline techniques, Otmar Scharrer.
“When it comes to torque density, we’re on the high of the rostrum after we examine ourselves with e-drives for passenger vehicles presently out there in the marketplace. On the identical time, we paid sturdy consideration to the sustainability facet throughout growth.”
The electrical motor works with out heavy uncommon earths and the thermal administration system doesn’t use fluorine-based coolant. The diminished variety of parts and the general 30 per cent discount in system weight is pitched as a double bonus.
One other space of focus was the thermal administration system with three designated circuits, which was designed largely to chop the quantity of power sucked out of the battery on chilly winter days.
A central unit and software program management all thermal processes for the driveline and passenger compartment alike, whereas a propane-based 800V warmth pump ought to use considerably much less power.
Certainly, ZF claims the battery vary will increase by as much as a 3rd in “demanding winter operation”, whereas on the different finish of the spectrum the considerably higher cooling efficiency makes the upper steady output of the e-machine potential.
On the software program entrance ZF developed its personal powertrain coding that networks all car techniques with one another and establishes connection to the cloud.
The driveline software program may also anticipate optimum working factors from particular person driving profiles and prime the system accordingly. It ‘learns’ the behaviour of drivers and might anticipate possibilities by way of an AI-based cloud service. Spooky.
MORE: Contained in the suppliers – ZF
