Custom traction drives: The platform for the future of mobility

Redefining drive technology Custom traction drives: The platform for the future of mobility

2024-04-08 From Michael Richter | Translated by AI 4 min Reading Time

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The foundation of the modern automotive industry is innovation, cost pressure, and sustainability. ZF stands out here with its innovative developments in electromobility. In an exclusive interview with Dr. Otmar Scharrer, head of development for electric drive systems at ZF, we delve deep into the world of electric drives.

Concept vehicle EVbeat: ZF has trimmed its ultra-compact electric drive package EVSys800 with thermal management and software in the EVbeat concept vehicle for maximum efficiency.(Image: ZF) — Concept vehicle EVbeat: ZF has trimmed its ultra-compact electric drive package EVSys800 with thermal management and software in the EVbeat concept vehicle for maximum efficiency.
(Image: ZF)

Image 2: Dr. Otmar Scharrer is responsible for the development of electric drives at ZF.
(Image:ZF)

ZF's focus on individual customer needs is a unique selling point with such a vast range of vehicle classes. Therefore, ZF's technology platform is a remarkable approach to allow customers individuality. The platform is the result of years of research and development aimed at creating a modular and flexible solution for electric drives. This platform enables ZF to offer customized solutions for a broad range of applications. By combining various technology modules, specific requirements for performance, efficiency, and cost can be met effectively.

Sustainability and efficiency in focus with the I²SM.

In 2023, ZF introduced the inductively excited synchronous electric motor (FSM) with the I²SM. "The magnet-free motor made big waves," says Dr. Scharrer. "We actually have a long tradition with asynchronous machines. Our first electric drive that we put into series production was an asynchronous machine and this technology still has its raison d'être." Asynchronous machines are ideal for all-wheel drive vehicles where you drive many miles using only two driven wheels to save energy.

Gallery

The world's most compact and torque-dense electric motor without magnets and rare earths: ZF is developing a sustainable and high-performance alternative to popular electric drives with the I2SM concept.(Image: ZF)

The new generation of ZF's EVSys800 electric drive impresses with a power density of 70 Newton meters per kilogram of drive weight.(Image: ZF)

As long as there is no current flowing in the stator winding, the asynchronous motor does not generate any magnetic flux in the rotor. Therefore, there is no resistance, as would be the case with a synchronous motor with permanent magnets, explains Scharrer. This advantage is also offered by externally excited synchronous motors (FSM).

These advantages of the asynchronous machine are implemented by ZF within the framework of the technology platform with the I²SM. "The biggest advantage in terms of sustainability - you don't need magnets. After all, that's one to two kilos of magnetic material that is installed there [...] In addition, they are found in the People's Republic of China 95 percent of the time and some people are therefore thinking about whether it makes sense to make themselves so dependent on a single country." In terms of costs, however, this has not really had an effect on the drive or power electronics yet, because the external excitation requires an additional motor phase and increased software effort. However, independence from raw materials is not to be sneezed at in times of crumbling supply chains.

The key technology behind the compact design is inductive transmission. Here, the voltage for the rotor winding is induced, making comparable measures such as slip rings superfluous. In addition, the positioning integrated by ZF allows for a significantly shorter design. A full 90 mm is saved here.

Variety through modular design: asynchronous, synchronous, and externally excited.

Within the technology platform, ZF offers various types of engines. The selection of the appropriate technology is based on a thorough analysis of the customer's specific requirements. For example, asynchronous motors offer a robust and cost-effective solution, while externally excited synchronous machines enable high efficiency and performance while being independent of rare earths. By using specialized simulation tools and comprehensive expertise, ZF is able to recommend the optimal configuration for each application. Their own simulation tools make it possible to analyze driving cycles and select the best machine accordingly.

For the EVbeat, ZF built a technology carrier based on the Porsche Taycan. This vehicle was not just simply assembled. Through several thousand simulations, the ideal combination of front and rear axle was found to get the last bit of performance or efficiency. With success. The EVbeat achieves up to a third more range in real winter operation. Here, a Permanent Magnet Synchronous Motor (PSM) without heavy rare earths was installed with the EVSys800. This is also part of the technology platform.

In addition to increasing independence in the area of magnetic materials, ZF is also partnering with Wolfspeed in the area of power semiconductors. Through the close partnership, the supplier secures exclusive market access. In the EVSys800, power semiconductors in the inverter are used with silicon carbide technology.

"If I were a startup, I would buy the electric drive from ZF and not develop it myself." Scharrer's statement is based on the fact that it is difficult to diversify with electric drives, especially at the beginning. According to Scharrer, it makes little sense for startups, which still have low sales, to develop their own drives due to the high investment costs and the high amount of time required.

Cooling as a Central Element

A central element of the technology platform is the cooling. "We have decided to cool where the heat is generated, namely in the copper wires of the winding." The heat is removed directly from the system through oil, which flows around the windings of the electric machine. The demand-based cooling also allows for a significantly more compact design. Through in-house developments such as TherMaS, a thermal management system, independent cooling of the electric motor and power electronics is also facilitated.

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Date: 08.12.2025

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Shaping the future

Flexibility and adaptability are key factors for success in the fast-paced mobility industry. This technology platform represents a central building block of ZF's strategy to be able to respond to the rapidly changing requirements of the market. Not only are customer-specific solutions efficiently developed with this system - it also lays the foundation for new trends such as autonomous driving, electrification, and digitalization. It is a living system, continually being developed to redefine the boundaries of what is possible. (mr)