Innovative Products from ZF E-Mobility - Efficieny - Performance

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

2 Topics Product Strategy Efficiency Econnect OTA 2 E-Mobility Electric Drive Performance Intelligent Wheel Dynamics

3 Topics Product Strategy Econnect OTA 3 Electric Drive Intelligent Wheel Dynamics

4 ZF Technological Leadership Systems Partner With Complete Vehicle Expertise Partial Functionality Vehicle Network Modules / Systems Transmission System Axle System Units Transmissions Steering System OTA 4 Components Starting Components Chassis Components

5 Global Megatrends Globalization Demographic Change OTA 5 Urbanization Mobility New Ecology

6 Optimization of Conventional Powertrain Optimization Conventional Powertrain Reduction of Energy Consumption and Emissions Traffic / Transport / Mobility Hybrid Drive Electric Drive Lightweight Design Power Generation Alternative Energy 9 HP cpower 8 HP OTA 6

7 Hybrid Drives Reduction of Energy Consumption and Emissions Traffic / Transport / Mobility Power Generation Optimization Conventional Powertrain Hybrid Drive Electric Drive Lightweight Design Alternative Energy AVE130 8 P 70 H 3rd Generation EcoLife Hybrid OTA 7

8 Electric Drives / Alternative Energy Optimization Conventional Powertrain Reduction of Energy Consumption and Emissions Traffic / Transport / Mobility Hybrid Drive Electric Drive Lightweight Design Power Generation Alternative Energy etb RW1 EVD1 OTA 8

9 Lightweight Design Optimization Conventional Powertrain Reduction of Energy Consumption and Emissions Traffic / Transport / Mobility Hybrid Drive Electric Drive Lightweight Design Power Generation Alternative Energy Rear axle concept with wheel guide GRP transverse (leaf) spring Brake Module Plastics suspension strut Plastics damper top mount Plastics pneumatic spring Plastics wheel carrier OTA 9

10 Topics Product Strategy Econnect OTA 10 Electric Drive Intelligent Wheel Dynamics

11 The Disconnect Idea Benefits by 4WD increased traction improved handling and safety improved drivetrain response In-line 4WD-driveline Disadvantages by 4WD package space and integration added weight increased fuel consumption and CO 2 emission East-West 4WD-driveline Improving fuel consumption by temporarily disconnection of 4WD components OTA 11

12 ZF-Demonstrator for ECOnnect CO 2 -reduction up to 3-5% at full AWD-performance when AWD is not needed, its losses are switched off RDU twin clutch system (without differential) Functionalities: Torque distribution on demand Torque Vectoring Traction improvement RDU and PTO as implemented in ZF demo vehicle (Land Rover Freelander) PTO Ring Gear disconnect by dog clutch Functionalities: bring rear driveline to stand still Almost complete disconnect of rear driveline, Proven drag torque reduction up to 93% (related to standard units)! OTA 12 strategy-based, fast and imperceptible changeover between 2WD/AWD Driver has full AWD-performance in all relevant driving situations

13 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 Option for basic version OTA 13 RDU - Basic AWD-clutch on one output shaft used for active torque distribution and AWD-disconnect

14 Connecting sequence of ZF ECOnnect 1. Synchronize propshaft 2. Engage dog ring 3. Build up of rear axle torque PTO 50 ms to 100 ms 40 ms to 70 ms 100ms RDU ms E-Motor position controlled connection sequence Fast, reliable and silent activation process under all driving conditions OTA 14

15 Performance of traction Improvement by individual torque transfer low mue Hang-on AWD Twin clutch AWD low mue limited traction brake intervention required increased torque on µ-high smooth and relaxed operation full locking capabilities in longitudinal and transversal direction Improved traction and gradability even under severe slip conditions OTA 15

9% drag related saving NEDC cycle mid-sized SUV gasoline engine Simulation derives a pure

16 Simulation of CO 2 saving P total losses = P drag torque + P gear efficiency - 5.3% - 2.3% - 4.7% total saving CO 2 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% CO ² The ZF-Disconnect System achieves an overall reduction of -4.7% CO 2 OTA 16

17 Topics Product Strategy Econnect OTA 17 Electric Drive Intelligent Wheel Dynamics

18 Motivation iwd OTA 18

19 iwd Improved Safety and Driving Dynamics optimization of tire forces by active systems Wheel position control OTA 19

20 Target Setting stability intervention definition vehicle characteristic improved agility improved traction brake intervention yaw torque yaw torque driving stability driving safety OTA 20 comfort

21 Target Setting stability intervention definition vehicle characteristic improved agility improved traction agility yaw torque safety fuel consumption critical tire/road contact OTA 21

22 Target Setting stability intervention definition vehicle characteristic improved agility improved traction improved traction regarding straight driving and cornering! driving stability driving safety traction OTA 22

23 iwd Improved Safety and Driving Dynamics optimization of tire forces by active systems Wheel position control OTA 23

24 iwd Improved Safety and Driving dynamics optimization of tire forces by active systems Wheel position control OTA 24

25 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 AKC (Active Kinematic Control) Control Arm with adjustable Length design electric motor gear box fail-safe lock ball-type linear drive OTA 25

26 iwd Improved Safety and Driving Dynamics optimization of tire forces by active systems Wheel position control OTA 26

27 Torque Vectoring Axle Drive Vector Drive input brake planetary gear OTA 27 torque vector unit differential torque vector unit

28 Concept Vehicle with interacting Systems AWD Vector Drive AS ERC AKC OTA 28

29 Influence on Self-Steering Characteristics steady-state 2004 im Kurzprofil circular test * influence Active Steering agility at low v veh comfort at high v veh influence Torque Vectoring Lenkradwinkel [ ] conventional Active Steering AS Torque Vectoring TV interaction AS & TV gets higher with rising v veh optimized tire force * Radius 100m, Versuchsstrecke Nardo (Februar 2007) OTA 29 distribution influence interaction self-steering char. adjustable in all areas adjustable range lateral acceleration [m/s 2 ] velocity v veh [km/h]

30 Topics Product Strategy Econnect OTA 30 Electric Drive Intelligent Wheel Dynamics

31 Driveline Electrification Terms, Classes, Functions, Steps (Micro Hybrid) Mild Hybrid parallel Full Hybrid parallel (serial, power split) Plug-In-Hybrid Electric Vehicle Range Extension ICE Driving Stop/Start Regeneration/ Boosting Electric Launch Electric Driving (regen energy) Electric Driving (with external energy) Pure Electric Driving Electric driving speeds Step 0 Step 1 Step 2 small medium all ICE driving speeds OTA 31 all / some

32 8HP70 Driveline integrated Hybrid One package: Torque converter, Hybrid module 8P70H OTA 32

33 Electric Drive Designed by ZF Base vehicle and design data Design weight (incl. driver and partial load) Axle torque Axle power (maximum during acceleration) kg Nm 90 kw Gradeability 35 % Maximum speed (equivalent power: 30 kw) Acceleration km/h 150 km/h < 10 s OTA 33

34 Motor technology and speed considerations ASM Motor weight [kg] OTA PSM Design focus Equivalent motor speed at 150 km/h [rpm]: Final edrive ratio i ( ) Effect: light-weight and compact solution due to high speed approach

35 ZF s EVD1 for Small Passenger Cars Specifications: Performance: max. 90 kw / 30 kw cont. Axle torque: approx Nm Max. Speed: rpm Characteristics: Single-speed two-step transmission: i = 16 Compact, light weight: 45 kg Power density: 2,0 kw/kg Optimized acoustics Scaleable up to: 130 kw / Nm axle torque OTA x 325 x 250 mm

36 Testing Vehicle for EVD1 OTA 36

37 E-Vehicle based on Suzuki Splash / Opel Agila EVD1 Testing Vehicle ZF Stromos with EVD1 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 OTA 37

used to understand and improve the acoustic behavior No

38 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 OTA 38 FE Model

39 EVD1 Outlook Integration levels for central electric drive Cooler Axle drive Integration Level 1 Integration Level 2 CAN Power electronics E-Motor Transmission OTA 39 Battery Progress will be made by overall system optimization and integration

40 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 OTA 40

41 Thank you very much for your attention! OTA 41

Into the Future WIth e-mobility ZF ProDuCtS For hybrid AnD electric VehICleS

Into the Future With e-mobility ZF PRODUCTS FOR HYBRID AND ELECTRIC VEHICLES Contents Electric mobility page 4 a megatrend with potential Diversity in efficiency: page 6 electrification of the driveline