ZF's latest by-wire tech to go on show at IAA Mobility 2023

At the IAA Mobility 2023 in Munich, starting September 5, technology group ZF will focus on its range of by-wire technologies. ZF has one of the most comprehensive portfolios of purely electronically controlled steering, brake, or suspension systems for software-defined vehicles. These chassis systems no longer require mechanical connections or system fluids. Also purely electric is the future ultra-compact and lightweight 800-volt drive with world-beating torque density.

“Our by-wire systems open the door to a new era of vehicle control,” said Dr. Peter Holdmann, head of ZF’s Car Chassis Technology division. “Connected chassis systems for longitudinal, lateral and vertical dynamics can improve drive dynamics, and ZF is uniquely positioned in the market with its range of actuators and functions also for the combination of all three dimensions of vehicle dynamics.” Purely electronically controlled and networked by-wire systems offer better vehicle control, shorter braking distances, more steering flexibility, greater driving stability at high speeds, and increased range and efficiency.

ZF is a leading developer and manufacturer of by-wire systems that do not require a direct mechanical connection:

- Steer-by-wire including rear-axle steering
- Brake-by-wire with integrated brake control
- Electronically controlled, active damping
- The combination of these technologies leads to networked chassis systems that can be coordinated holistically with the cubiX software.

The EVSys800 is a modular 800-volt drive and consists of silicon carbide power electronics, the electric motor and a reduction gearbox.

Compact and lightweight 800-volt drive

In June 2023, ZF presented the future 800-volt drive EVSys800 as a preview of the IAA Mobility. The EVSys800 is a modular 800-volt drive and consists of silicon carbide power electronics, the electric motor and a reduction gearbox.

Despite its extremely compact design and light weight, the EVbeat does not skimp on performance: The concept vehicle has a maximum torque of 5200 Newton metres available on the rear axle – and this with a uniquely high torque density for road-legal passenger cars with of 70 Newton meters per kilogram. The continuous and peak power of the electric motor is 206 and 275 kilowatts, respectively – ZF thus achieves continuous power of around 75 percent of the peak power.

In terms of dimensions, the drive saves 50 millimetres in width thanks to the compact reduction gearbox and the ZF-patented ‘Braided Winding’ technology of the electric motor, thus enabling space-saving, coaxial installation on the drive axle.

With a total weight of 74 kilograms, the EVSys800, normalised to the same output as the latest ZF 800-volt series drive, is about 40 kilograms or 30 percent lighter.