ZF unveils a new thermal management system for electric vehicles, sets new standards in EV range and efficiency

ZF, a technology company, has unveiled its self-developed thermal management system for electric vehicles (EVs) at its annual Global Technology Day event. The system has the potential to increase the range of EVs in the winter by up to one-third. It features an optimised electric drivetrain, including power electronics, a motor, and a reduction gearbox based on 800-volt silicon carbide. According to the company, this innovative system sets new standards in terms of compactness and weight, while the newly developed powertrain software improves efficiency.

Automakers can integrate the thermal management system into their vehicles in a variety of ways thanks to the modular design. ZF has demonstrated the next generation of electric drive with thermal management in a demonstration vehicle called the EVbeat, which is based on a Porsche Taycan concept electric vehicle (EV). This vehicle was unveiled to journalists from around the world at ZF's Friedrichshafen headquarters during the company's Global Technology Day event.

Feats with the EVbeat demonstration vehicle

The EVbeat demonstration vehicle showcased an electric driveline that combined optimised components into a cohesive system. This design helped it achieve a remarkable 30 per cent weight reduction, enabling a high torque density of 70 Nm/kg of drive weight, which currently stands as the highest value among road-legal passenger cars on the market. “Just a few months ago it was only a vision, now our drive can be experienced in a sports car,” said Dr Holger Klein, CEO of ZF.

The company boasts that it has already received customer orders for its all-electric Steer-by-Wire steering system from major world markets. The tech company also said that automotive manufacturers from Asia, Europe, and America have expressed interest in integrating ZF's cubiX chassis software and the first-generation 800-volt electric drive into their vehicles in the coming months.

A new chassis division

ZF is combining its divisions for active safety technology and passenger car chassis technology to create the comprehensive Chassis Solutions division in recognition of the importance of chassis technologies. This division brings together the necessary hardware components and software for controlling a vehicle's vertical, longitudinal, and lateral dynamics. This new division is set to launch in January 2024 and will cater to various mobility segments, including commercial vehicles and industrial applications.

The future vision of ZF

According to ZF, its 'Next Generation Mobility' strategy is in line with customer demand for cleaner, safer, more comfortable, and cost-effective mobility solutions. ZF provides systems for passenger cars, commercial vehicles, and industrial technology. With approximately 1,65,000 employees worldwide, ZF reported sales of €43.8 billion in the financial year 2022. The company operates 168 production locations across 32 countries.