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ZF showcases new eMobility kit for commercial e-mobility; AxTrax 2 drives

ZF’s Commercial Vehicle Solutions (CVS) division presented its latest eMobility kit, which now includes all-electric central drives, axle drives and eComponents. Suitable for light-, medium- and heavy-duty vehicles and trailers, the integrated, modular e-driveline systems enable quiet and emission-free operation. AxTrax 2, AxTrax 2 dual and the previously launched CeTrax 2 dual electric central drive were recently both demonstrated at ZF’s Global Technology Day in Friedrichshafen.

With our modular electric drive kit, ZF can provide customers with everything they need to electrify their commercial vehicles from last-mile delivery vehicles up to 44-ton truck. The kit consists of scalable axle and central drive systems. Like other ZF electric systems, they can be easily combined with different electrification technologies, such as batteries or fuel cells, for example. The kit is complemented by a wide range of eComponents that have been developed and produced in-house.

—Winfried Gründler, Senior Vice President of Driveline Systems with ZF’s Commercial Vehicle Solutions division

AxTrax 2 maximizes the available space for cargo or the passenger cabin as well as for batteries and enhances the manufacturer’s design flexibility for future vehicle concepts. The electric drives can be fully synchronized with key vehicle functions, such as braking, ADAS and automated driving systems, to help enhance vehicle safety and efficiency. It also enables advanced digital and telematics systems to exchange information with the e-axle via CAN bus.

AxTrax 2 is offered in two variants. AxTrax 2 for commercial vehicles enables a continuous power of 210 kW. The AxTrax 2 dual variant, with two integrated e-motors, is suited for heavy-duty applications and offers 380 kW continuous power.

2023-07-10_3_ZF-AxTrax-2-dual

AxTrax 2 Dual: Continuous power of 380 kW


Both models are designed to replace the engine, transmission, drive shaft and conventional axle to electrify a commercial vehicle. This line-up enables opportunities to reimagine commercial vehicle form, function, and architecture, enhancing aerodynamics, enabling automated driving or adding extra battery capacity.

By leveraging a unique, scalable and modular platform approach, ZF can help customers to electrify all classes of commercial vehicle platforms, from existing to all-new vehicle platforms.

Used as an electric drive axle in semitrailers, AxTrax 2 can recover electrical energy when braking. The energy is temporarily stored in a battery and can be used by the electric axle to support the truck drive. Recuperating energy in this way also helps to reduce fuel or energy consumption as well as carbon emissions. At the same time, the safety of the truck-trailer combination is improved.

ZF also offers electric components that have been specifically designed to meet the requirements of the commercial vehicle market. The modularity allows manufacturers to use ZF’s complete electric drive systems, or alternatively, combine them with their own components while taking advantage of synergies and common interfaces. These include the e-motor (PSM), the silicon carbide (SiC) inverter, the e-drive control unit, the e-actuator and the multi-speed transmission.

Comments

yoatmon

I would question the location of the brake discs. It appears that they are all else than maintenance friendly.

JamesDo88039200

Disks are usually out inside the wheels where airflow for cooling is maximized those disks are in the industry standard position. Go look inside the wheels of your car the disks will be just inside the wheel rim right on the hubs. Why? That's where the airflow is the greatest to cool the disks that can run into the 500+ degree range during heavy braking. Jaguar had a number of models that mounted the disks to the differential in the center line of the car. I owned such a model a V12 XJ Vanden the rear disks had a nasty habit of overheating and glazing over or sticking the pads melted to the disks due to their location and lack of airflow.


Theses ZF axles look perfect to do a diesel electric hybrid like a locomotive but with a super capacitor for braking regen. Run the diesel at peak efficiency to charge the supercap then shut down for a few miles of travel and also while coasting. Regen allow braking energy to the supercap. Mileage should go up at least 30% in some cases 60% or more. Take a F150 sized truck put one of these 200kw on the rear axle. Put in a small 100kw 3cyl clean diesel hooked to a 100kw generator use a high density axial flux generator with induction coupling to the rotor so no rare earth elements are needed for perm mags. Run that little.engine hard at 80% rated load and 45+% BSFC Eff. Then shut it down and draw power from your supercap for a few miles. Only run the diesels at its peak BSFC point make up the rest of the power needed from the supercap for acceleration. Modern ultracaps are approaching nickel metal hydride cells in energy density but with hundreds of thousands of full discharge cycles. These researchers have ones coming in at lithium ion densities at lower current per gram of material at a realistic 25 A per gram they would be in NMHyd levels so a 4 kwh pack is around 50kg.

https://www.ncbi.nlm.nih.gov/pmc/articles/PMC6409971/

A F150 sized truck in real.world driving has been returning 2.7 miles per kwh not towing a load at 50_65 mph avg speeds. So a 4 kwh ultra capacitor would take it 10 miles. To charge that cap you.need to run that little 3cyl at 80kw for 4.15 minutes then you can shut it down. That takes into account the 1.3MJ per minute you use to move at an avg 60mph with a 2.7 mile per kwh real.world economy of use. If you were sitting at a stop light it would.be 3 min while stationary with an 80kw net output into a 4kwh pack. So a 4/10 duty cycle at a steady 60mph to keep the engine at its peak bsfc point. Less when you include the added regen energy.

The other choice is to run the engine continuously while at motorway speeds in that case it needs to put out 22kw which is one fifth it's rated output modern diesel BSFC maps show that's in the 30_35% range depending on rpm vs torque load point. Why point that out because you could parallel hybrid the vehicle by driving the front tires using a simple differential and single speed reduction gearbox. You actually loose mpg doing this at light loads since you could saw tooth duty cycle run the engine at its peak bsfc point like above.

The benefit of parallel hybrid comes in under heavy loaded condition where now you need 50 to 80kw to pull the load on a continuous basis at speed. This is smack in the middle of the minimum BSFC heart for this sized engine you could gain 3_5% better energy efficiency by skipping the generator to inverter to motor path and just go crankshaft to single reduction gear to wheels. The added benefit is four wheel drive at all times the engine is clutched to the wheels. In addition to having the ability to.engine compression (Jake) brake down long and steep inclines this is critical feature for truck's under heavy load descending grade. when the pack is full you either have to friction brake or engine brake this holds true for every ICE truck as well down grade it's friction brake or engine brake.
BEV truck's if the pack is near full charge and they head down hill and regen fills the pack is they must friction brake the whole rest of the way down this is potentially a life threatening situation. As no engine compression braking is possible in a pure BEV truck. There should be a mandate for resistance banks like on alocomotive for BEV truck's to be able to dump charge via those banks to heat and keep using regen down a grade continually. Otherwise the friction brakes can and will overheat and a runaway truck is guaranteed at that point not.fun been there done that in a ICE truck with no Jake brake had to use the runaway truck gravel pull out and nearly ran off the curves on the way to it.

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