ZF-EVmore: Efficiency thought holistically

Power-on-demand drive concept, reduction of critical raw materials, 800-volt technology: With the EVmore, the ZF technology group is demonstrating what is actually possible in terms of maximizing efficiency in an electric vehicle.

A good way to increase efficiency is to reduce losses. The engineers at ZF know that too. With the EVmore, the tech group is now setting new standards. With an efficiency of 96.3 percent from the battery to the wheels, the drive concept of the Stromer achieves a new benchmark value for near-series technology. What does this number mean? 96.3 percent of the energy from the battery actually goes to the wheels. For comparison: current market announcements about future drive efficiencies are at 95 percent.

Power on demand

This is made possible by a sophisticated electric drive concept. A newly developed, highly efficient drive works on the front axle. The so-called eConnect system is used on the rear axle, which activates or decouples a rear axle drive as required.,

In practice, it looks like this: At a constant speed - for example on a section of motorway with a speed limit - this is brought about by a permanently excited synchronous motor (PSM) driven front axle pushes the EVmore forward. The supporting asynchronous motor (ASM) on the rear axle is only activated in certain situations in order to be able to call up peak performance – for example when overtaking. eConnect then switches on the second drive within milliseconds, providing additional e-power.

Focus on sustainability

Speaking of power: The particularly efficient PSM motors use magnets that generate a static magnetic field in the rotor. This is the only way the rotor can synchronize with the magnetic field of the surrounding stator. In order to achieve the highest possible energy density, the industry mainly uses permanent magnets made of so-called heavy rare earths. In the EVmore, ZF almost completely dispenses with their use. Only traces of terbium can be detected in the magnets of the rotor on the main drive axle. This step saves costs, reduces the import dependency of critical raw materials and protects the environment.

The significantly reduced proportion of heavy rare earths can lead to thermal instability of the magnets. Thanks to eConnect, the non-magnetic secondary drive on the rear axle intervenes in support of intensive continuous stress on the front axle.,

At the same time, ZF is replacing the conventional two-stage gearbox with intermediate and output shaft on the front axle of the EVmore with a newly developed single-stage model .Thanks to helical gears and the omission of the intermediate shaft with bearings, not only is its weight reduced by up to 15 percent, but also the number of friction points - and less friction means less energy loss. Even at a speed of 100 km/h, 50 percent of the losses occurring in the transmission can be saved in this way.

But new cars are no longer just about their drive. The software-defined vehicle is increasingly coming to the fore in a digitized world. The engineers therefore developed special drive software for the EVmore. This controls the two motors on the front and rear axles depending on the driving situation. The driver no longer has to choose between eco or sport mode, the software constantly determines what the driver wants and optimizes the powertrain in every driving situation between maximum efficiency and maximum performance.

Long loading times goodbye

For the EVmore, the technology group also uses its proven, modular eDrive kit. This kit also includes electric motors for popular vehicles with 800-volt batteries. Such a drive is accommodated in the EVmore. Thanks to the charging power of up to 350 kW, the 800-volt technology enables significantly shorter waiting times at the column.,

With the EVmore, ZF provides answers to current mobility questions: New drive concept, sustainable implementation, quick charging, short stops - efficiency thought holistically.

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