ZF-AVE 130 Presentation en

AVE 130 Electric Portal Axle
TU Axle & Transmission Systems for Buses & Coaches

ZF Friedrichshafen AG
1 TU_1503_en AVE 130 Electric Portal Axle ZF Friedrichshafen AG, 2015

Agenda
1. Electromobility Framework Conditions

2. E-Mobility in the City Bus
3. AVE 130: System Benefits
4. AVE 130: Technology
5. AVE 130: Customer Value
6. AVE 130: Applications

Agenda


Product Strategy between
Growth and Scarcity of Resources
Challenges and conflicting targets
Scarcity of
resources
Population
growth
Growth Resources
energy demand
Increasing
Economic
Energy
growth
Water Raw materials
raw materials
demand for
Urbanization
Increasing
Food
Increasing

transport
awareness
volume
Environ-
mental
E-Mobility:
Influencing Factors
E-mobility is a market trend
ENVIRONMENTAL
PROFITABILITY
PROTECTION
Influencing factors
E-mobility
LEGISLATION
E-Mobility in the Commercial Vehicle:
Framework Conditions
2015 2020 2025 2030
Temporary driving
bans for city centers
Fleet CO2 emission
Light commercial vehicles
Zero-emission zones
CO2 emission
Commercial vehicles > 6 t
Zero-emission cities
Strong increase in passenger car e-mobility

Significant decrease in component prices
Battery technology: improved power-to-
T weight ratio, range, costs

echnology
Fuel cell vehicles:

H2 filling stations, passenger car volume production (2017),
Hydrogen as a source of energy
Storage medium for renewable energy sources

Agenda


E-Mobility in the City Bus:
Roadmap
Megacity / city
Conventional diesel engine

D
Serial/parallel/plug-in hybrid
D
E
Central motor
Wheel motors
E
19xx 2015 2025 ~2035

E-Mobility in the City Bus:
Drive Solutions
Electric bus drive types
Central motor + AV 133 AVE 130 with

integrated wheel motors

E-Mobility in the City Bus
Comparison of Solutions in the Markets
Wheel motors
ZF wheel motors
Criterion Central motor by other
AVE 130
manufacturers
System + + +
Service network 0 - +
Weight - - +
Performance + - +
Bus design - + +
Standard components + - +
Safety - - +

Agenda


ZF AVE 130 Electric Portal Axle
System Scope
AVE 130 system expansion

AVE 130 Drive control
axle (hardware &
software)
ZF Torque
system supply control
Inverter (hardware & software) Vehicle control (HCU)

List of inverters released Vehicle operation strategy
Battery management
by ZF
Auxiliary control
and others
Inverter suppliers
OEM

Global Service Network
ZF Services locations worldwide

32 service companies
5 Marketing offices
650 service partners
www.zf.com/servicenetwork
* Countries with ZF Services locations are highlighted in dark grey

Weight
Weight advantage compared to a Weight advantage compared to

AVE 130
central motor other wheel motors
Electric motors Small, high-speed asynchronous

are integrated in the axle motors Total weight only
No separate motor suspension Lighter than permanent 1 220 kg
is required synchronous motors without
transmission
No motor mounting elements
are required Weight-optimized axle bridge and
More space in
standard spring carrier
No propeller shaft is required the interior
Result:
increased installation
space and weight Possible weight
advantages reduction
by up to 500 kg

Performance
AVE 130: 400 V AC vs. wheel motors Articulated bus

with 2 driven axles
(by other manufacturers)
More than 80 % starting torque increase
11 000 Nm compared to 6 000 Nm

Possibility to drive an articulated bus with only one driven axle
Hill starts with 15 % gradient possible Articulated bus

with 1 driven axle
Reduced costs and weight
Only one driven axle incl. power electronics
Pusher
Puller

Bus Design Compared to the Central Motor
Neither a separate motor nor a prop shaft are required

Increased load capacity The bus can also be implemented
as a puller version with only one
More space in the bus, for
axle
example for
Further improvement of low-floor
passengers/seats
design
stowage compartments
lower axle bridge
additional batteries/units
no differential
Optimized design in the interior
Different axle bridge
of the bus
lengths are possible
Better weight distribution
Same design for left and right-
hand drive

Use of Standard Components
AVE 130 mounting conditions compared to AV 133 mounting conditions
Identical interfaces make it possible to use
standard v-links and trailing links

standard spring carriers
standard air springs
AV 133
standard dampers
standard rims and wheels
AVE 130
Use of
identical disk brakes

identical wheel bearings
A further lowered axle bridge makes it possible to
further reduce the floor height

Towing Safety
AVE 130
Permanent synchronous motors
(asynchronous motor)
Not safety-critical It is necessary to short-circuit the motor or to lock and
pull up the driven axle
It is enough to turn off the voltage at the inverter.
Where applicable, the propshaft flange connection
Low drag torques (only wheel motors)
must be disconnected
Otherwise high, dangerous voltages will be
induced

Agenda


Concept and System Elements
Concept: high-speed asynchronous motor in combination with 2 gear ratios

1st step 1st step
Ring gear portal with power split
and input gear at the bottom 2nd step
2nd step
Planetary drive with 4 planet gears
All gears are helical toothed for max. noise optimization
Essential system elements

Asynchronous motors, water-cooled, recirculation cooling Wheel head
on the inside, "highly integrated" (the electric motor does
not have its own housing) Overall ratio 22.66
Ring gear portal with power split (patented)
Ppeak = 2 x 125 kW
with i = 3.895 and planet gear stage i = 5.818
Pcont. = 2 x 60 kW
nmax. = 11 000 rpm
ncont. = 10 300 rpm (80 km/h at 275/70 R 22.5)

Characteristic Data of the Traction Motor
Characteristic data for each ZF traction motor 400 V AC

Traction motor with asynchronous technology 3 phases
Shift system Y
Nominal voltage AC (terminal, n > 4 100 rpm) 400 Veff
Nominal current (phase winding) 115 Aeff
Max. current (phase winding, 20 sec.) 350 Aeff
Nominal power 60 kW
Max. power 125 kW
Max. torque 485 Nm
Max. speed 11 000 rpm (10 300 rpm cont.)
Number of pole pairs 2
Max. frequency 371 Hz
Power factor 0.83
Class of insulating material H/180 C
Electric Interface Requirements
Requirements concerning the electric

400 V AC
interfaces: traction motor drive inverter
Typical rated voltage DC 650 V
Operating range voltage DC 300 - 750 V
De-rating 300 - 580 V
Normal operation 580 - 750 V
Continuous current AC, phase winding 250 Aeff
Maximum current (20 sec.) AC, phase winding 350 Aeff
Fundamental frequency 2 - 371 Hz
Pulse frequency 2 - 8 kHz
De-rating 2 - 5 kHz
Normal operation 6 kHz

28 Ton Articulated Bus with AVE 130 400 V AC
Tractive Force/Speed Diagram
Vehicle data:
1x AVE 130 400 V AC
GVW = 28.0 t
froll = 0.009
A = 6.3 sqm
Cw = 0.55
rdyn = 0.466 m
i = 22.660
Intermediate circuit voltage 650 V DC
Installed power:
Fuel converter 200 kW
Generator power 200 kW
Energy accumulator 250 kW
Available traction power (DC):

Fuel converter 151 kW
Energy accumulator 200 kW
Power requirements
Auxiliaries (DC): 40 kW

Agenda


Advantages for the Vehicle Manufacturer
Applicable for all electric drive concepts and

energy sources (energy accumulators)
Diesel-electric
Fuel cell
Overhead contact line
Diesel hybrid: considerable fuel savings
Regeneration of braking energy

Downsizing of the diesel engine
Diesel hybrid: purely electric starting
Low-noise
Zero emission

Use of standard components
Identical with the AV 133 portal axle

Drive power
125 kW per wheel motor

Articulated buses can be implemented with only one driven axle
Up to 500 kg of weight savings
Integration of the electric motors in the axle

No separate motor suspension components
No propshaft
The complete AVE weighs only 1 220 kg

Increased bus design freedom
Integration of the electric motors in the axle

Optimized design in the interior of the bus
More space for batteries and/or other components
Increased passenger carrying capacity
Suspension points similar to those of the standard axle
(AV 133)

Advantages for Fleet Operators
More space in the interior of the bus
Increased passenger carrying capacity
Use of standard components
Identical with the current AV 133

Input torque
11 000 Nm per wheel

Articulated bus with only one driven axle is possible

Advantages for Fleet Operators
Zero-emission driving
Smooth and continuously variable starting
Low-noise
Vibration-free driveline
No propeller shaft
Simple wheel change
Global service network

Agenda


Flexible for any Drive System
Suitable for all electric energy sources

Battery
In hybrid applications, considerable fuel

savings are possible thanks to regenerative
braking and downsizing of the combustion
engine
Purely electric starting is possible with diesel-
electric hybrid applications
Fuel cell
Trolleybus (overhead contact line) Battery
Hybrid: fuel
Hybrid: diesel-
cell/
electric/battery
battery
Overhead contact line/ Overhead contact line/

battery diesel-electric

Applications
City buses, more than 350 axles delivered
EvoBus/Germany
Solaris/Poland
Foton/China
Ankai/China
Bozankaya/Turkey
Trolza/Russia

Special vehicles, for example airport
applications
(prototype catering vehicle available)
Waste collection vehicles
(project discussion)
Field Population
More than 350 AVE 130 in operation > 10 million km mileage
Bremen Darmstadt Dortmund Dresden Duisburg Essen Hamburg
Karlsruhe Krefeld Leipzig M-Gladbach Mhlheim Munich Stuttgart
Wuppertal Beijing Milan Moscow Rotterdam Seoul Switzerland

History
1994 to 1997: first ZF portal axles with wheel hub drive
17 articulated buses for the UITP Congress in Stuttgart

Since 2004 further development of the wheel hub drive
Increase of the power per wheel head to 125 kW

Change from air to water cooling
Noise optimization with improved gearing
Continuous improvement of noise characteristics,
robustness, and performance
Optimization of volume production assembly
Increase of terminal voltage from 350 V AC to 400 V AC
Start of volume production planned for 2016

Thank you very much for your attention!
ZF Friedrichshafen AG behlt sich smtliche Rechte an den gezeigten technischen Informationen einschlielich der Rechte zur Hinterlegung von Schutzrechtsanmeldungen und an daraus entstehenden Schutzrechten im In- und Ausland vor.
ZF Friedrichshafen AG reserves all rights regarding the shown technical information including the right to file industrial property right applications and the industrial property rights resulting from these in Germany and abroad.

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AVE 130 Electric Portal Axle

TU Axle & Transmission Systems for Buses & Coaches

1 TU_1503_en AVE 130 Electric Portal Axle ZF Friedrichshafen AG, 2015

1. Electromobility Framework Conditions

2 TU_1503_en AVE 130 Electric Portal Axle ZF Friedrichshafen AG, 2015

1. Electromobility Framework Conditions

3 TU_1503_en AVE 130 Electric Portal Axle ZF Friedrichshafen AG, 2015

Challenges and conflicting targets

Water Raw materials

E-mobility is a market trend

2015 2020 2025 2030

Strong increase in passenger car e-mobility

T weight ratio, range, costs

Fuel cell vehicles:

6 TU_1503_en AVE 130 Electric Portal Axle ZF Friedrichshafen AG, 2015

1. Electromobility Framework Conditions

7 TU_1503_en AVE 130 Electric Portal Axle ZF Friedrichshafen AG, 2015

Conventional diesel engine

19xx 2015 2025 ~2035

Electric bus drive types

Central motor + AV 133 AVE 130 with

9 TU_1503_en AVE 130 Electric Portal Axle ZF Friedrichshafen AG, 2015

10 TU_1503_en AVE 130 Electric Portal Axle ZF Friedrichshafen AG, 2015

1. Electromobility Framework Conditions

11 TU_1503_en AVE 130 Electric Portal Axle ZF Friedrichshafen AG, 2015

AVE 130 system expansion

Inverter (hardware & software) Vehicle control (HCU)

12 TU_1503_en AVE 130 Electric Portal Axle ZF Friedrichshafen AG, 2015

ZF Services locations worldwide

13 TU_1503_en AVE 130 Electric Portal Axle ZF Friedrichshafen AG, 2015

Weight advantage compared to a Weight advantage compared to

Electric motors Small, high-speed asynchronous

14 TU_1503_en AVE 130 Electric Portal Axle ZF Friedrichshafen AG, 2015

AVE 130: 400 V AC vs. wheel motors Articulated bus

11 000 Nm compared to 6 000 Nm

Hill starts with 15 % gradient possible Articulated bus

15 TU_1503_en AVE 130 Electric Portal Axle ZF Friedrichshafen AG, 2015

Neither a separate motor nor a prop shaft are required

16 TU_1503_en AVE 130 Electric Portal Axle ZF Friedrichshafen AG, 2015

AVE 130 mounting conditions compared to AV 133 mounting conditions

Identical interfaces make it possible to use

standard v-links and trailing links

identical disk brakes

17 TU_1503_en AVE 130 Electric Portal Axle ZF Friedrichshafen AG, 2015

18 TU_1503_en AVE 130 Electric Portal Axle ZF Friedrichshafen AG, 2015

1. Electromobility Framework Conditions

19 TU_1503_en AVE 130 Electric Portal Axle ZF Friedrichshafen AG, 2015

Concept: high-speed asynchronous motor in combination with 2 gear ratios

Essential system elements

20 TU_1503_en AVE 130 Electric Portal Axle ZF Friedrichshafen AG, 2015

Characteristic data for each ZF traction motor 400 V AC

Requirements concerning the electric

22 TU_1503_en AVE 130 Electric Portal Axle ZF Friedrichshafen AG, 2015

Intermediate circuit voltage 650 V DC

Available traction power (DC):

23 TU_1503_en AVE 130 Electric Portal Axle ZF Friedrichshafen AG, 2015

1. Electromobility Framework Conditions

24 TU_1503_en AVE 130 Electric Portal Axle ZF Friedrichshafen AG, 2015

Applicable for all electric drive concepts and

Regeneration of braking energy

25 TU_1503_en AVE 130 Electric Portal Axle ZF Friedrichshafen AG, 2015

Use of standard components

Identical with the AV 133 portal axle