ZF readies multi-speed electric vehicle drive units to improve efficiency, reduce weight

Well-known German automotive supplier ZF has announced improved versions of its modular drive units for electric vehicles.

The revised, second-generation components are expected on the market in 2025 to reduce the development time for manufacturers of the latest battery-electric vehicles by several months.

ZF claims the units – known as 'e-drives' – will be built in three basic configurations for passenger cars and light commercial vehicles. It consists of a motor, inverter, controllers, transmission and software, with optimisations to reduce cost and size, and improve performance.

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Unlike off-the-shelf solutions for internal combustion vehicles, ZF says its electric motor can be customised to meet the demands of an OEM.

The electric motor will support 400-volt and 800-volt configurations, with increased power density using oil-flow cooling. It says this will increase the continuous power rating to 85 per cent of peak power, allowing smaller motors to be fitted for improved efficiency.

This is achieved through the use of braided windings in the motor, decreasing volume by 10 per cent and allowing for a reduction in the use of heavy and expensive rare earth materials.

To further improve efficiency and performance, ZF has developed an integrated planetary gearbox with a combination of forward and reverse speeds, as seen in the Porsche Taycan.

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The two-speed automatic transmission will support a "fully integrated differential function", potentially allowing for axles to turn in opposite directions, similar to the upcoming Mercedes-Benz EQG's tank turn.

However, efficiency is the most important selling point, with a two-speed gearbox allowing for a taller gearing ratio to lower an electric vehicle's RPM at highway speeds.

ZF expects its 'e-drives' to commence sales to potentials customers such as BMW, Audi, Porsche, in 2025, however, it said individual components will enter production before that.

According to the German-based brand, it has an order bank equivalent to €25 billion (AU$38.7 billion).