1. automotive and vehicles
2. electric vehicles

ZF Friedrichshafen AG
Ernst-Sachs-Straße 62
D-97424 Schweinfurt
Germany
Phone:+49 9721 98-0
Fax: +49 9721 98-2290
www.zf.com
Electric Motors
for Hybrid Drives
For Passenger Cars
Driveline and Chassis Technology
© ZF Friedrichshafen AG-PC&CV-Electric Motors-09/2011
and Commercial Vehicles
1
Comfort, Performance, Environmental
Protection: Powertrain Components
and Systems for Passenger Cars and
Commercial Vehicles
Hybrid Module
The demands placed on suppliers in the automotive sector are changing dramatically. Increasingly, suppliers are being called upon to integrate components into
complex systems – a development task that can only succeed on the basis of close
partnerships with vehicle manufacturers. The future will bring continued demands
for reduced fuel consumption, emissions, weight and installation space, along with
enhanced comfort, safety, and driving dynamics. To meet these goals, innovative
solutions and new products are essential.
The hybrid module combines ZFs’ core areas of exper-
A special highlight is the possibility of integrating the
tise in the driveline – the electric motor, torsional dam-
module into existing driveline architectures without
ping, and wet clutch – superbly integrated and mutually
taking up additional installation space.
ZF has taken responsibility here, demonstrating expertise in generating comprehensive solutions with its integrated powertrain systems. In doing so, it consistently
pursues a systems approach in developing and manufacturing new products and
technologies that represent real advances. ZF provides overall solutions that meet
the demands of overall systems.
DynaStart®, the electric motor from ZF, forms the basis
effectiveness, and functionality in conjunction with the
for electrifying the driveline. Used in passenger cars,
other hybrid system components. The electric motor is
commercial vehicles and construction machines, the
available with internal or external rotor, depending on
electric motor ensures outstanding efficiency, cost-
the needs of individual applications.
adjusted.
DynaStart®
One example: As a powertrain specialist and manufacturer of electric drives,
ZF can also provide superior integration for the full spectrum of hybrid powertrain
designs and thus offer production-ready solutions that are already reducing fuel
consumption and emissions for the vehicles of tomorrow.
Electric drives: The DynaStart® product range
External
diameter
[mm]
Electric
active length
[mm]
Max. current
[A]
Max. torque
[Nm]
Max. n
[rpm]
SG269
270
80
440
230
6,500
SG345
345
110
350
500
4,500
SG430
430
160
350
1,100
4,500
External
diameter
[mm]
Electric
active length
[mm]
Max. current
[A]
Max. torque
[Nm]
Max. n
[rpm]
SG280
280
55
230
165
6,500
SG280
280
75
240
265
6,500
SG325
325
56
325
210
6,500
Internal rotor type
0
0
200
50
400
100
600
150
800
200
External rotor type
0
10
100
20
200
30
300
40
400
50
■ Voltage [V]
■ Max. power [kW]
2
3
Hybrid Technology – Future-oriented
and Environmentally Friendly
Installation concepts for electric motors
of parallel hybrid drivelines in cars
Front-longitudinal
Front-longitudinal
motor positionmotor position
Front-transverse
Front-transverse
motor positionmotor position
Front-longitudinal
Front-longitudinal
motor
motor
position
position
More than ever before, our society is focus-
Comprehensive experience in powertrain technology at ZF en-
ing on preserving the environment, the cli-
sures that these new systems can also be integrated into existing
mate, and fossil fuels. ZF has been working
power-trains in order to meet all energy conversion and vibrational
together with car makers for years now on
damping requirements. This integration expertise, which allows to
hybrid strategies that significantly lower fuel
combine the entire range of powertrain functions into complex sys-
consumption and CO2 emissions. A num-
tems, is the key to introducing hybrid technology on a broad scale.
Front-transverse
Front-transverse
motor
motor
position
position
ber of systems are already ready for series
production, and they also set new standards
for cost-efficiency.
Hybrid module operations
Ready
Ready
Ready
forfor
start-stop
forstart-stop
start-stop
operation:
operation:
operation:
Dynamic
Dynamic
Dynamic
starter:
starter:
starter:
Recuperation:
Recuperation:
Recuperation:
The
The
The
electric
electric
electric
motor
motor
motor
is is
running,
isrunning,
running,
and
and
and
can
can
can
start
start
start
upup
the
upthe
the
combustion
combustion
combustion
engine
engine
engine
in in
fractions
infractions
fractions
of of
aof
second
a asecond
second
byby
engaging
byengaging
engaging
thethe
the
start-up
start-up
start-up
clutch.
clutch.
clutch.
The
The
The
start-up
start-up
start-up
clutch
clutch
clutch
is is
engaged,
isengaged,
engaged,
and
and
and
thethe
the
torque
torque
torque
brings
brings
brings
thethe
the
engine
engine
engine
to toto
thethe
the
right
right
right
torque
torque
torque
level
level
level
in in
less
inless
less
than
than
than
0.20.2
0.2
second.
second.
second.
Brake
Brake
Brake
energy
energy
energy
is is
not
isnot
not
wasted
wasted
wasted
asas
heat,
asheat,
heat,
but
but
but
rather
rather
rather
stored
stored
stored
asas
electric
aselectric
electric
energy.
energy.
energy.
Boost:
Boost:
Boost:
Coasting
Coasting
Coasting
mode:
mode:
mode:
Purely
Purely
Purely
electric
electric
electric
drive:
drive:
drive:
When
When
When
starting
starting
starting
upup
up
oror
or
accelerating,
accelerating,
accelerating,
the
the
the
combustion
combustion
combustion
engine's
engine's
engine's
torque
torque
torque
is is
is
boosted
boosted
boosted
byby
by
torque
torque
torque
from
from
from
the
the
the
electric
electric
electric
motor.
motor.
motor.
Especially
Especially
Especially
atat
at
low
low
low
rpm
rpm
rpm
levels,
levels,
levels,
this
this
this
can
can
can
fillfill
fill
gaps
gaps
gaps
inin
in
the
the
the
combustion
combustion
combustion
engine's
engine's
engine's
torque
torque
torque
curve.
curve.
curve.
For
For
For
full
full
full
use
use
use
ofof
of
roll
roll
roll
energy,
energy,
energy,
e.g.
e.g.
e.g.
onon
on
downhill
downhill
downhill
gradients.
gradients.
gradients.
Touching
Touching
Touching
the
the
the
gas
gas
gas
pedal
pedal
pedal
retrieves
retrieves
retrieves
full
full
full
engine
engine
engine
function.
function.
function.
For
For
For
example,
example,
example,
driving
driving
driving
inin
in
noise
noise
noise
protected
protected
protected
oror
or
non-emission
non-emission
non-emission
zones,
zones,
zones,
oror
or
when
when
when
maneuvering
maneuvering
maneuvering
inin
in
tight
tight
tight
spaces.
spaces.
spaces.
Electric drives: Overview
Mild hybrid
Power [kW]
Torque [Nm]
Voltage [V]
Ready
Ready
Ready
forfor
for
start-stop
start-stop
start-stop
operation:
operation:
operation:
External diameters [mm]
Electric active length [mm]
Fuel reduction
Functions
4
Delivery truck
City bus
PlugIn hybrid
Full hybrid
Full hybrid
4–20
20–70
50–100
25–130
100–200
100–250
100–500
100–500
250–600
500–1,200
42–450
120–650
250–650
150–650
560–720
240–345
Recuperation:
Recuperation:
Recuperation:
240–480
345–480
240–325
Dynamic
Dynamic
Dynamic
starter:
starter:
starter:
240–345
50–80
55–105
55–105
55–105
100–200
up to 15 %
up to 30 %
up to 50 %
up to 50 %
up to 35 %
Generator
Start-stop
Boost
The
The
The
electric
electric
electric
motor
motor
motor
is is
running,
is running,
running,
and
and
and
can
can
can
start
start
start
upup
up
the
the
the
combustion
combustion
combustion
engine
engine
engine
Recuperation
inin
in
fractions
fractions
fractions
ofof
of
a second
aa second
second
byby
by
engaging
engaging
engaging
the
the
the
start-up
start-up
start-up
clutch.
clutch.
clutch.
Electrical range [km]
Full hybrid
Passenger car
Generator
Generator
Start-stop
Start-stop
Boost
Boost
The
The
The
start-up
start-up
start-up
clutch
clutch
clutch
is is
engaged,
is engaged,
engaged,
and
and
and
the
the
the
torque
torque
torque
brings
brings
brings
the
the
the
engine
engine
engine
toto
to
Recuperation
Recuperation
the
the
the
right
right
right
torque
torque
torque
level
level
level
inElectric
in
in
less
less
less
than
than
than
Electric
drive
drive
0.2
0.2
0.2
second.
second.
second.
operation
operation
1...5
15...45
Generator
Generator
Start-stop
Start-stop
Boost
Boost
Brake
Brake
Brake
energy
energy
energy
is is
is
not
not
not
wasted
wasted
wasted
asas
as
heat,
heat,
heat,
but
but
but
rather
rather
rather
stored
stored
stored
asas
as
electric
electric
electric
energy.
energy.
energy.
Recuperation
Recuperation
Electric drive
Electric drive
operation
operation
1...5
1...5
5
The Hybrid Module –
Integrating all Operations
The system: Hybrid module characteristic degree of efficiency
(Udc 202 V, electric)
300
250
Booster torque
200
The task:
The technology:
Hybrid drives combine the high torque of
The permanent excited synchronous motor that was developed
electric drives at low rpm levels with the
by ZF features extremely short axial dimensions and superior
dominant torque of combustion engines
power. The module‘s operations include vibration damping, tor-
at high rpm ranges. Putting the efficiency
que transmission, dynamic starter, clutch actuation, and electric
and emission advantages into practice
power generation. Its starter clutch separates the powertrain
Combustion engine
150
of components across the entire range of
to operate fully electrically and to convert braking energy into
operating conditions. In particular, the
electric energy without loss of friction in the combustion engine.
0
relatively high degree of technical com-
The hybrid module enables the combustion engine to be started
0
plexity – due to two drivelines in a single
with minimal electromotor torque. During start-up, the electric
vehicle – requires a network approach that
motor accelerates the rotor and the clutch disc in fractions of a
links different system structures.
second. The clutch then engages and the inertia of the rotating
24
22
20
18
16
14
93 %
10
8
Electric drive with 25 kW
at 202 nom. V
50
from the combustion engine, which allows the vehicle both
26
12
100
requires mastering the complex interplay
Mechanical power [kW]
Torque [Nm]
Power boost: More torque
92 %
91 %
89 %
87 %
83 %
6
80 %
4
2
Booster operation
1,000
2,000
0
3,000
4,000
0
1,000
2,000
3,000
4,000
5,000
rpm [1/min]
6,000
rpm [1/min]
masses boosts the combustion engine up to or even above idling
ZF is developing hybrid drives that meet
rpm. This process takes place so quickly that drivers don‘t even
this systems approach.
notice it. The clutch has torque transfer capability of levels over
1,000 Nm.
The hybrid module from ZF: Integrated into the existing transmission architecture
Hybrid module consisting of
electric motor, booster clutch, and actuator
Benefits
■■ Dramatic reduction in fuel consumption
and emissions
■■ Very fast and quiet engine start and
therefore comfortable start-stop operation
■■ Recuperation of electric energy from braking
■■ Improved driving dynamics thanks to
power boost for combustion engine during
acceleration
■■ Purely electric operation (no emissions)
by separating the combustion engine from
the driveline
Engine separator clutch
The engine separator
clutch ensures comfortable
separation or activation of
the combustion engine
Electric motor
The electric motor ensures high
performance density with optimum
efficiency
Transmission input hub
Torsional damping
to reduce torsional
vibrations
Engine side
6
Stator laminated core with coils
Rotor with permanently
excited magnetic poles
Transmission side
7
Integration Expertise
Installation space saved
As a result of joint research and develop-
Thanks to its expertise in powertrain components,
ment work with vehicle manufacturers
ZF Friedrichshafen AG can integrate start-up, shift, vibrational
and other partners ZF has developed mild
damping, and actuation elements. For example, the extremely
and full hybrids with both internal and
flat starter clutch with sin-tered facings make powerful hybrid
external rotors. These electric drives can
solutions possible for front-transverse applications as well. This
be integrated into new or already existing
ensures not only environmental but also economic advantages
powertrains without sacrificing any known
for vehicle manufacturers.
Integration solution
Benefits
■■ Greater efficiency and cost effectiveness
■■ Simple adaptation and integration
■■ Considerable installation space saved
compared to conventional solution
driveline functions.
– 30 %
Power Electronics – Key Components
for More Efficiency in the Driveline
ZF offers modularly scalable systems from
a single source for the electrification of the
driveline. Products ranging from the complete hybrid system and defined assemblies
to single components such as the inverter
or DC/DC converter can be provided. The
added value of a modular construction
system from a single source for ZF customers: They can optimally integrate their own
systems into the provided environment and
the consistent system design accelerates the
design and development of new variants.
0
20
40
60
80
100
120
140
160
180
200
Length [mm]
Conventional solution
Electric motor
Torsional damper
Clutch
Addition installation space (releaser)
8
9
DynaStart® – The Basis for
Hybridization in Passenger Cars
The task:
ensures a high degree of cost-effectiveness for vehicle manufac-
As a specialist for start-up elements, ZF
turers, because they can continue to work with existing vehicle
has been developing electric motors for
concepts. The DynaStart® starter generator from ZF has been
parallel hybrids that meet extremely high
specially developed for parallel hybrid solutions – short instal-
demands for performance density and cost
lation length, high energy efficiency, and sufficiently robust to
effectiveness. Ambitious fuel consumption
achieve superior results in the complex environment between
targets and reductions in CO2 emissions
the engine and the transmission.
can be reached – combined at the same
time with improvements in driving perfor-
The DynaStart® starter generator is available with an internal or
mance and comfort.
external rotor. Permanently excited neodymium iron boron mag-
Performance density
Benefits
■■ Optimum performance and torque density
■■ High torque at low rpm levels: start-up, start-stop
■■ Minimum axial length, smallest installation space
requirements
■■ Available with external or internal rotor
55 mm
Electric active length
nets are used so no electric current is needed to excite the field.
The technology:
This means that the power electronics can be smaller. In contrast
The first mild hybrid entered series pro-
to conventional electric motors, completely automatically wound
duction in Europe in 2009 with a starter
coils are used on specially formed laminated cores. This robust
generator from ZF. With an installation
design allows for cost-effective series production.
Compact and powerful – only two of many features that characterize the DynaStart® electric motor from ZF.
length of 65 mm and 15 kW of power, the
DynaStart® electric motor is helping to re-
Electric motors have been produced in Schweinfurt for standard-
duce fuel consumption and CO2 emissions
series applications since May of 2008 – and with every use they
by up to 15%. Thanks to no additional in-
make a substantial contribution to reducing emissions and con-
stallation space requirements, ZF also
serving resources.
Rotor with permanently
excited magnetic poles
Stator laminated core
with coils
DynaStart® – Electric motor for passenger cars
Engine connection
Mild hybrid SG325
Technical data
■■ Permanently excited
synchronous machine
■■ External operating principle,
air-cooled
■■ Fixed installation on crankshaft
■■ External diameter 325 mm
■■ Motor power 12 kW
(for 105 V and 6,000 rpm)
■■ Maximum cold-start torque
220 Nm (for 325 A)
10
11
DynaStart® – Economical Solution
for Commercial Vehicles
Connection to power electronics
Stator laminated core
with coils
The task:
The technology:
Use of urban delivery vehicles, city buses,
Designed as a full hybrid and embedded in transmission systems
and construction machines are all domi-
from ZF Friedrichshafen AG, the DynaStart® electric motor pro-
nated by fuel-intensive, frequent start-up
vides torque levels of up to 1,200 Nm with a maximum power of
and operating procedures and short driv-
200 kW. Extensive tests ensure operational safety and suitability
ing distances. This yields an enormous
for daily use. This means no limits in driving performance or com-
potential for saving fuel costs and the pos-
fort even for purely electric operations. Despite its high level of
sibility of significantly reducing exhaust
power, DynaStart® is integrated into existing transmission archi-
and noise emissions. In short, the ideal
tecture with no additional installation space requirements.
Rotor with permanently
excited magnetic poles
area of application for hybrid vehicles.
For construction machines, driving operations represent the
secondary area of application. For them, the primary benefit of
driveline electrification is to support auxiliary drives or to run
them entirely.
DynaStart® – Electric motor for commercial vehicles
Hybrid transmission systems: HyTronic for trucks (1),
EcoLife for buses (2), S-Matic for agricultural machines (3),
and ERGOPOWER for construction machines (4)
1
3
12
Benefits
■■ Optimum economic returns from
hybridization
■■ Reduced fuel consumption, exhaust
emissions, noise emissions
■■ Outstanding overall performance
for delivery vehicle, city bus, and
construction machine applications
■■ Greater cost effectiveness
■■ Use of proven technologies
■■ Production of sophisticated hybrid
transmission systems
2
4
13
Passenger Car
Product Portfolio
Commercial Vehicle
Product Portfolio
Powertrain Technology
Chassis Technology
Powertrain Technology
Chassis Technology
Transmissions
Axles
Transmissions
Axles
Manual and automatic transmissions
transmissions
Dual clutch
Front and rear axle systems
Corner modules
Chassis Components
Driveline Components
Gearshift systems
Clutch systems
flywheels
Damper modules and damping systems
Electronic components
Torque converters
Axle drives
Differentials
Manual and automatic transmissions
Hybrid systems
Front and rear axle systems
Hybrid systems
Dual-mass
Bevel gear sets
Powertrain suspension systems
Stabilizers
Stabilizer links
Suspension joints
Tie rods
Control arms
Wheel carriers
systems
Crash-absorption elements
mounts
Precision plastics parts
Leveling
Chassis
Electronic
Driveline Components
Chassis Components
Gearshift systems
Damper modules and damping systems
Steering systems
converters
Electronic components
Clutch systems
Dual-mass flywheels
Retarder systems
Differentials
Axle drives
Torque
PTOs
Bevel gear sets
Powertrain suspension systems
V-links
Torque rods
Suspension joints
mounts
Tie rods
Stabilizers
Cabin suspensions
Precision plastics parts
4-point links
Chassis
Electronic
components
components
Steering Systems
Steering Systems
Hydraulic power steering systems
Mechanical, hydraulic, and electric power steering
systems
Steering pumps
Steering columns
systems
Steering pumps
Rear-axle steering
Steering columns
Steering accessories
Steering accessories
8HP, 9HP, HIS, AKC, VECTOR-DRIVE, ARS, CDC, and DynaStart are registered
trademarks of ZF Friedrichshafen AG. Servolectric is a registered trademark
of ZF Lenksysteme GmbH.
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