ZF has announced that it is leading the way in developing smarter, more connected, and highly efficient technologies for commercial vehicles by harnessing the power of software.
As the automotive industry increasingly embraces digital integration, it positions itself as a key enabler of smart and connected technologies. The company leverages its extensive software expertise across various vehicle segments to quickly and cost-effectively produce intelligent systems, lowering the overall total cost of ownership (TCO).
Braking, e-Drive Synergy Programme
One of its notable initiatives is the Braking and e-Drive Synergy Programme, which optimises the synergy between electric driveline and braking functions. This innovative system not only extends the range of electric vehicles by harnessing energy during deceleration but also reduces the size of the batteries needed. The programme integrates ZF’s next-generation e-drives, the AxTrax 2 dual and CeTrax 2 dual, with the mBSP XBS advanced braking system. This integration allows the e-drive to function as an actuator for the braking system and vice versa, controlling both acceleration and braking.
The system maximises energy recuperation, recharging onboard batteries during driving and effectively extending the vehicle's range. It also offers 'one-pedal-drive' functionality, enhancing driving comfort, especially in low-speed manoeuvres common in urban driving and yard vehicle applications. Additionally, the system improves launch capabilities by optimising traction control, reducing tyre wear, and enhancing vehicle performance and stability on slippery surfaces.
Software Brake Resistor
ZF has also developed an innovative software solution that replaces traditional hardware brake resistors in battery electric vehicles. This new function intelligently limits the maximum energy content of the battery in specific charging situations. It uses location data to determine if the vehicle is likely to descend a steep gradient, where significant additional battery charge can be generated through regenerative braking. The system ensures the battery saves capacity during charging, allowing for maximum energy harvesting during descent, while fully charging the battery in other situations.
This software solution eliminates the need for bulky and heavy brake resistors, saving approximately 150kg of weight and increasing available space within the chassis. By maximising energy efficiency and making all energy available for propulsion, the system improves efficiency and sustainability, showcasing how intelligent server-cloud-based functions can reduce costs and weight while enhancing performance.
Through these advancements, ZF continues to demonstrate its commitment to innovation in commercial vehicle technology, offering solutions that improve efficiency, safety, and sustainability in the automotive industry.
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