At its International Know-how Day in Friedrichshafen, ZF presented the electrical idea car EVbeat, which is designed for optimum compactness, low weight, and most effectivity in actual operation. On this ZF electrical car, 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 car
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 car relies on a Porsche Taycan and takes main collection 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 light-weight weight, the EVbeat doesn’t skimp on efficiency. The idea car 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 vehicles 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
By way of 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 collection drive, is about 40 kilograms or 30% lighter and thus contributes considerably to the load financial savings of the idea car.
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 move straight 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, using heavy uncommon earths may be distributed with, and the electrical motor may be produced extra sustainably. The ‘Braided Winding’ expertise developed and patented by ZF, is an additional growth of the wave winding and allows a complete of 10% much less set up house. The winding head alone is as much as 50% smaller than with typical approaches. This protects round 10% copper.
The inverter of the electrical drive has been essentially redesigned and all important parts have been essentially revised. Vital enhancements have been achieved in every of the areas of electromagnetic compatibility, energy modules and capacitors by way of set up house, weight and sustainability.
Inverter with SIC expertise
A brand new, coaxial discount gearbox transmits the drive forces of the electrical motor by way of two planetary gear units. They not solely generate the specified remaining drive ratio, but in addition carry out the absolutely built-in differential operate.
Coaxial discount gear
In contrast with typical offset ideas, through which the enter and output shafts will not be on the identical axis, the coaxial answer reduces weight and set up house necessities with out compromising on effectivity, noise and vibration. Together with Braided Winding expertise, this drive may be made considerably shorter, permitting set up in virtually any car set up house.
Thermal administration. The temperature management of a car can account for a big proportion of its power necessities in winter, which may be between three and 6 kilowatts, particularly when heating up. Nice coolness in summer season and heat in winter are main consolation components for the occupants. The best temperature can also be an important issue for the efficiency of the electrical motor, the facility electronics and the battery.
TherMaS
The primary central thermal administration system (TherMaS) developed by ZF for electrical autos is built-in into the EVbeat idea car. 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 power. As a result of it’s compact and easy in design, it may be simply built-in into autos.
The TherMaS idea has three designated circuits for the primary time: On the middle 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 car areas resembling 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 at present. If required, the central refrigerant circuit serves two individually controllable cooling circuits through 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 facility and charging electronics. The management software program regulates the cooling capability.
As a consequence 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 potential.
Powertrain software program: effectively community car drive and cloud. The properties of the {hardware} methods lay an essential basis for the sustainable operation of the car; their optimum orchestration is achieved by way of the software program. ZF has developed its personal powertrain software program that networks all car methods with one another and establishes the connection to the ZF cloud.
As a result of the effectivity of an electrical motor is determined by its thermal working factors, it is very important preserve them within the optimum vary always: At low speeds and excessive torque necessities, the optimum thermal working level could be very low, whereas at excessive speeds with low torque necessities, excessive temperatures will not be an issue. Nevertheless, the thermal situations 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 may anticipate the likelihood of particular person driving profiles by way of an AI-based cloud service. For instance, air-con and system cooling are lowered when brief distances are detected.
On this foundation, the help system also can give drivers direct recommendation on the way to use the electrical car effectively. For instance, environment friendly acceleration and deceleration in addition to an optimized most pace are displayed. That is notably helpful in relation to calculating an correct and sensible vary earlier than the journey.
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