At its International Know-how Day in Friedrichshafen, ZF introduced the electrical idea automobile EVbeat, which is designed for optimum compactness, low weight, and most effectivity in actual operation. On this ZF electrical automobile, the parts of an e-driveline have been optimized and mixed right into a holistic system. These embody the 74 kg light-weight and ultra-compact driveline with a torque density of 70 N·m/kg, holistic thermal administration and cloud-networked driveline software program.
EVbeat idea automobile
At chilly temperatures round freezing level, the vary in real-world operation will increase by as much as a 3rd in contrast with present expertise.
The ZF EVbeat idea automobile is predicated on a Porsche Taycan and takes main sequence expertise from ZF and different market gamers as a benchmark.
EVSys800 e-drive. The EVSys800 used within the idea is a modular 800-volt drive and consists of SiC energy electronics, the electrical motor and a discount gearbox. Regardless of its extraordinarily compact design and lightweight weight, the EVbeat doesn’t skimp on efficiency. The idea automobile has a most torque of 5200 N·m accessible on the rear axle—and this with a uniquely excessive torque density for road-legal passenger automobiles with of 70 N·m per kilogram. The continual and peak energy of the electrical motor is 206 and 275 kilowatts, respectively—ZF thus achieves steady energy of round 75% of the height energy.
EVSys800
When it comes to dimensions, the drive saves 50 millimeters in width because of the compact discount gearbox and the ZF-patented Braided Winding expertise of the electrical motor, thus enabling space-saving, coaxial set up on the drive axle.
E-Motor Stator with new braided winding.
With a complete weight of 74 kilograms, the EVSys800, normalized to the identical output as the most recent ZF 800-volt sequence drive, is about 40 kilograms or 30% lighter and thus contributes considerably to the burden financial savings of the idea automobile.
Important for that is the electrical motor with a brand new cooling idea and a brand new winding expertise. For cooling, ZF permits oil to movement instantly across the copper rods precisely on the level the place most warmth is generated throughout operation. Such extremely environment friendly cooling considerably will increase efficiency with the identical weight and set up house.
As well as, the usage of heavy uncommon earths might be allotted with, and the electrical motor might be produced extra sustainably. The ‘Braided Winding’ expertise developed and patented by ZF, is an extra improvement of the wave winding and permits a complete of 10% much less set up house. The winding head alone is as much as 50% smaller than with standard approaches. This protects round 10% copper.
The inverter of the electrical drive has been basically redesigned and all important parts have been basically revised. Vital enhancements have been achieved in every of the areas of electromagnetic compatibility, energy modules and capacitors when it comes to set up house, weight and sustainability.
Inverter with SIC expertise
A brand new, coaxial discount gearbox transmits the drive forces of the electrical motor through two planetary gear units. They not solely generate the specified closing drive ratio, but in addition carry out the absolutely built-in differential perform.
Coaxial discount gear
In contrast with standard offset ideas, during which the enter and output shafts usually are not on the identical axis, the coaxial resolution reduces weight and set up house necessities with out compromising on effectivity, noise and vibration. Together with Braided Winding expertise, this drive might be made considerably shorter, permitting set up in virtually any automobile set up house.
Thermal administration. The temperature management of a automobile can account for a big proportion of its vitality necessities in winter, which might be between three and 6 kilowatts, particularly when heating up. Nice coolness in summer time and heat in winter are main consolation components for the occupants. The best temperature can also be a necessary issue for the efficiency of the electrical motor, the ability electronics and the battery.
TherMaS
The primary central thermal administration system (TherMaS) developed by ZF for electrical automobiles is built-in into the EVbeat idea automobile. TherMaS makes use of a central unit and clever software program to regulate all thermal processes for the driveline and passenger compartment. The brand new design considerably reduces house necessities and weight in comparison with earlier approaches for cooling and heating e-cars. A propane-based 800-volt warmth pump additionally requires considerably much less vitality. As a result of it’s compact and easy in design, it may be simply built-in into automobiles.
The TherMaS idea has three designated circuits for the primary time: On the heart is the very small refrigerant circuit. That is pre-filled and hermetically sealed and is subsequently maintenance-free. As well as, the idea has no interfaces to different automobile areas akin to the inside. ZF makes use of the fluorine-free, pure refrigerant propane.
Though solely half the earlier refrigerant is used, the cooling capability will increase by an element of two in contrast with refrigerants generally used as we speak. If required, the central refrigerant circuit serves two individually controllable cooling circuits during which frost-protected water flows as regular: The primary is designed for the comparatively excessive temperatures of the electrical motor, whereas the second regulates the temperature of the ability and charging electronics. The management software program regulates the cooling capability.
Because of this total thermal administration, the vary of the EVbeat will increase by as much as a 3rd in demanding winter operation. The considerably higher cooling efficiency makes the upper steady output of the e-machine attainable.
Powertrain software program: effectively community automobile drive and cloud. The properties of the {hardware} programs lay an vital basis for the sustainable operation of the automobile; their optimum orchestration is achieved through the software program. ZF has developed its personal powertrain software program that networks all automobile programs with one another and establishes the connection to the ZF cloud.
As a result of the effectivity of an electrical motor depends upon its thermal working factors, it is very important hold them within the optimum vary always: At low speeds and excessive torque necessities, the optimum thermal working level may be very low, whereas at excessive speeds with low torque necessities, excessive temperatures usually are not an issue. Nevertheless, the thermal circumstances can’t be established at brief discover. ZF’s driveline software program can anticipate the optimum working factors from the person driving profiles and put together the system accordingly.
It learns the conduct of drivers and might anticipate the likelihood of particular person driving profiles by way of an AI-based cloud service. For instance, air con and system cooling are diminished when brief distances are detected.
On this foundation, the help system can even give drivers direct recommendation on methods to use the electrical automobile effectively. For instance, environment friendly acceleration and deceleration in addition to an optimized most pace are displayed. That is significantly useful relating to calculating an correct and sensible vary earlier than the journey.