innovative products from zf - ucozgershon.ucoz.com/zf/charts_zf_workshop_valencia_2012.pdf ·...

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2Dr. Hans-Jörg Domian

ZF Friedrichshafen AG

Innovative Products from ZFE-Mobility - Efficieny - Performance

ZF-Technik WorkshopValencia, 22.-24. Okt. 2012

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Topics

Efficiency

Econnect

E-Mobility

Electric DrivePerformance

Intelligent Wheel Dynamics

Product Strategy

Innovative Technik von ZF - Valencia 12-10-22

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Econnect

Electric Drive Intelligent Wheel Dynamics

Product Strategy

Topics


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ZF – Technological LeadershipSystems Partner With Complete Vehicle Expertise

Components

Units

Modules /

Systems

Partial Functionality

Vehicle Network

StartingComponents

Transmissions

TransmissionSystem

ChassisComponents

Steering System

Axle System


OTA 5 © Z

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Global Megatrends

Demographic

ChangeGlobalization

UrbanizationNew

EcologyMobility


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Reduction of Energy Consumption and Emissions

Traffic / Transport / MobilityPower

Generation

OptimizationConventional

PowertrainHybrid Drive Electric Drive

Lightweight Design

Alternative Energy

Optimization of Conventional Powertrain

9 HP

cPower 8 HP


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Generation



Lightweight Design

Alternative Energy

Hybrid Drives

8 P 70 H

3rd Generation

AVE130 EcoLife Hybrid


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Generation



Lightweight Design

Alternative Energy

Electric Drives / Alternative Energy

eTB

RW1 EVD1


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Generation



Lightweight Design

Alternative Energy

Lightweight Design

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


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Topics

Econnect


Product Strategy


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The Disconnect Idea


Improving fuel consumption by temporarily disconnection of 4WD components

Benefits by 4WD

• increased traction

• improved handling and safety

• improved drivetrain response

Disadvantages by 4WD

• package space and integration

• added weight

• increased fuel consumption

and CO2 emission

In-line 4WD-driveline

East-West 4WD-driveline

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ZF-Demonstrator for ECOnnect

CO2-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

• Tractionimprovement

PTORing 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)!

strategy-based, fast and imperceptible changeover between 2WD/AWD

Driver has full AWD-performance in all relevant driving situations

RDU and PTO as implemented in ZF demo vehicle(Land Rover Freelander)

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ZF ECOnnect

PTO• separated input shaft by dog clutch• elektromechanic actuation

RDU - Basic• AWD-clutch on one output shaft• used for active torque distribution and AWD-disconnect

RDU – Sport• twin clutch system (without differential)• Locking- and Torque Vector-Functionality• 2 elektromechanic actors

ECOnnect

Option for

basic version

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Connecting sequence of ZF ECOnnect

PTO

RDU

1.Synchronize

propshaft

50 ms

to

100 ms

2.Engagedog ring

40 ms

to

70 ms

3.Build up of

rear axle torque

100ms

E-Motor position controlled connection sequence

Fast, reliable and silent activation process under all driving conditions

190 – 270 ms


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full locking capabilities in longitudinal and transversal direction

Improved traction and gradability even under severe slip conditions

Performance of traction Improvement by individual torque transfer

Hang-on AWD Twin clutch AWD

low muelow mue

• limited traction

• brake intervention required

• increased torque on µ-high

• smooth and relaxed operation


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Simulation of CO2 saving

• NEDC cycle

• mid-sized SUV

• gasoline engine

CO

2e

mis

sio

n[g

/km

]

-4.2% -2.3% -3.9% drag related saving

Ptotal losses = Pdrag torque + Pgear efficiency

Simulation derives a pure drag torque related saving potential of -5.3% CO²

The ZF-Disconnect System achieves an overall reduction of -4.7% CO2

- 5.3% - 2.3%

-4.2% -2.3% -3.9%

total saving- 4.7%


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Topics


Econnect


Product Strategy

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Motivation iWD


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iWDImproved Safety and Driving Dynamics


optimization of tire forces by active systems

Wheel position control

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Target Setting


brake

intervention

yaw

torque

yaw

torque

improved tractiondefinition vehicle characteristic

stability intervention improved agility

driving stability

driving safety

comfort

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Target Setting


yaw torque



agility

safety

fuelconsumption

critical

tire/road contact

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Target Setting


improved traction regarding straight driving and cornering!



traction

driving safety

driving stability

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iWDImproved Safety and Driving dynamics




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AKC® (Active Kinematic Control)Control Arm with adjustable Length

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


design

electric motor

gear box

fail-safe lock

ball-type linear drive

1

2

3

4

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torq

ue v

ecto

r unit

torq

ue v

ecto

r unit

differential

“brake“

planetary

gear

input

Torque Vectoring Axle Drive“Vector Drive”

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Concept Vehicle with interacting Systems

Vector Drive AS ERC AKCAWD

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Influence on Self-Steering Characteristics


* Radius 100m, Versuchsstrecke Nardo (Februar 2007)

2004 im Kurzprofilsteady-state circular test *

influence Active Steering

• agility at low vveh

• comfort at high vveh

10

20

30

40

50

60

70

80

90

Lenkra

dw

inkel [

°]

0 1 2 3 4 5 6 7 8 9 10

lateral acceleration [m/s2]

conventional

Active Steering ASTorque Vectoring TV

interaction AS & TV

influence Torque Vectoring

• gets higher with rising vveh

• optimized tire force

distribution

influence interaction

self-steering char.

adjustable in all areas

adjustable range

0 51 72 88 102 114velocity vveh [km/h]

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Driveline Electrification Terms, Classes, Functions, Steps


(Micro Hybrid)

Mild Hybridparallel

Full Hybrid parallel (serial, power split)

Plug-In-Hybrid Electric Vehicle

Electric driving speeds

– small medium all

ICE driving speeds

all – / some

ICE Driving

Stop/Start

Regeneration/Boosting

Electric Launch

Electric Driving(regen energy)

Electric Driving(with external energy)

Pure Electric Driving

Step 1

Range Extension

Step 2Step 0

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Driveline integrated HybridOne package: Torque converter, Hybrid module


8HP70 8P70H

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Electric Drive Designed by ZFBase vehicle and design data


Design weight (incl. driver and partial load) 1.250 kg

Axle torque 1.400 Nm

Axle power (maximum during acceleration) 90 kW

Gradeability 35 %

Maximum speed (equivalent power: 30 kW) 150 km/h

Acceleration 0-100 km/h < 10 s

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Motor technology and speed considerations


Equivalent motor speed at 150 km/h [rpm]:

8.000 13.000 21.000 26.000 40.000

ASM

PSM

0

10

20

30

40

50

60

6 10 16 20 30

Final eDrive ratio i (–)

Moto

r w

eig

ht

[kg]

Effect: light-weight and compact solution due to high speed approach

Design focus

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ZF’s EVD1 for Small Passenger Cars


Specifications:

Performance: max. 90 kW / 30 kW cont.

Axle torque: approx. 1.400 Nm

Max. Speed: 21.000 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 / 2.000 Nm axle torque

460 x 325 x 250 mm

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EVD1 Testing VehicleZF Stromos with EVD1


E-Vehicle based on

Suzuki Splash / Opel Agila

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

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EVD1 Acoustics


Vehicle tests Bench tests

FE Model

MBS Model

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

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EVD1 – Outlook Integration levels for central electric drive


Integration

Level 2

Integration

Level 1

Progress will be made by overall system optimization and integration

TransmissionCAN

Cooler

Battery

E-M

oto

r

Po

wer

ele

ctr

on

ics

Axle drive

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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

innovative products from zf - ucozgershon.ucoz.com/zf/charts_zf_workshop_valencia_2012.pdf ·...

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