ZF Unveils Compact, High Torque Drive System For Electric Cars
Behind the fancy nameplates on the cars we buy — Mercedes, BMW, Audi, and more — is an entire industry that supplies the parts and components that make those cars what they are. From seats and radios to touchscreens, windshields, and tires, suppliers bring the components needed to manufacture automobiles directly to the loading docks of vehicle factories around the world.
The company says its EVSys800 is a modular 800 volt drive unit that incorporates silicon carbide power electronics with the electric motor and a reduction gearbox. Compared to its current 800 volt drive unit, the EVSys800 is 40 kilograms lighter, which can result is a significantly lighter powertrain. Less weight under the hood means more capacity for people and things inside.
The new unit also eliminates the need for rare earth materials so the electric motor can be manufactured in a more sustainable manner. The “Braided Winding” technology developed and patented by ZF is a further development of so-called wave winding, and enables a 10% reduction in the space needed inside the motor housing. It also reduces the amount of copper required by about 10%. The inverter of the electric drive has been completely redesigned, as have all other essential components.
In addition to its new EVSys800 power unit, ZF has also developed a digitally controlled integrated heating and cooling system called TherMaS that is light weight and compact enough to fit into most of today’s vehicles. The heart of the system is an 800 volt heat pump that uses propane as the refrigerant.
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