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Engage with...ZF

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ZF is a global technology company that supplies systems for passenger cars, commercial vehicles and industrial technology, enabling the next generation of mobility. ZF allows vehicles to see, think and act. In the four technology domains Vehicle Motion Control, Integrated Safety, Automated Driving, and Electric Mobility, ZF offers comprehensive solutions for established vehicle manufacturers and newly emerging transport and mobility service providers.

ZF is a global technology company that supplies systems for passenger cars, commercial vehicles and industrial technology, enabling the next generation of mobility. ZF allows vehicles to see, think and act. In the four technology domains Vehicle Motion Control, Integrated Safety, Automated Driving, and Electric Mobility, ZF offers comprehensive solutions for established vehicle manufacturers and newly emerging transport and mobility service providers.

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  1. 1. © ZF Automotive UK Limited Driving the Electric Revolution Engage with.... ZF October 14th, 2021 Philip Langley | Dr. Connel Williams | Dr. David Moule
  2. 2. © ZF Friedrichshafen AG © ZF Automotive UK Limited ZF Group – Financial Overview 2020 October 14th, 2021 | Engage with .... ZF EUR 32.6 billion sales 153,522 employees EUR 2.5 billion Research & Development EUR 1.4 billion investments in property, plant, and equipment EUR 1.0 billion adjusted EBIT 2 3.2% adjusted EBIT margin
  3. 3. © ZF Friedrichshafen AG © ZF Automotive UK Limited Key Figures – Research and Development October 14th, 2021 | Engage with .... ZF 3 2.5 2.7 2.5 2.2 2017 2018 2019 2020 7.3% 6.7% 6.1% 7.7% Research and Development Expenditure in € billion / share of sales in % Output Invention Disclosures, Products and Product Applications 2,164 Invention Disclosures 133 New Products 579 Product Applications
  4. 4. © ZF Friedrichshafen AG © ZF Automotive UK Limited Sustainability Strategy – Measures to Achieve 2030 Targets October 14th, 2021 | Engage with .... ZF ZF Plants Supply Chain Products 100% green electricity all ZF Locations worldwide 90% steel from electric arc furnace, in Europe with DRI* from natural Gas 50% recycled material in ZF products >40% fully electrified Powertrain 50% CO2 neutral road transport in ZF logistics network Invest 3x more in energy efficiency (+xx% efficiency in 10 years) Setting the course for a sustainable future
  5. 5. © ZF Automotive UK Limited 5 ZF in the UK 2020 sales from ZF UK: € 1.7 billion >2,800 staff in UK as of end of 2020 Shirley ZF Hub UK £xx m Investment in new Tech Centre 9 locations Pontypool, Peterlee, Birmingham, Solihull, Darlaston, Nottingham, Wrexham, Shirley, Leeds Divisions of ZF operate in UK 7 of 9 ~1,000 Engineers in UK ∎ ∎ ∎ ∎ ∎ ∎ ∎ ∎ ∎ ∎ 2020 – ZF Acquires Wabco 2014 – ZF 1999 – TRW 1996 – LucasVarity PLC 1860 – Joseph Lucas & Sons Long UK Heritage ∎ October 14th, 2021 | Engage with .... ZF
  6. 6. © ZF Automotive UK Limited ZF Hub UK: Our new home from October 2021 Innovation for Next Generation Mobility October 14th, 2021 | Engage with .... ZF 6
  7. 7. © ZF Friedrichshafen AG © ZF Automotive UK Limited Servo drives Centre of Competence October 14th, 2021 | Engage with .... ZF 7
  8. 8. © ZF Friedrichshafen AG © ZF Automotive UK Limited Servo drives Centre of Competence October 14th, 2021 | Engage with .... ZF 8
  9. 9. © ZF Friedrichshafen AG © ZF Automotive UK Limited Automated Driving Vehicle Motion Control Integrated Safety Electric Mobility Next Generation Mobility - Now October 14th, 2021 | Engage with .... ZF 9 Steer by Wire Brake by Wire Rear steer Elec. Roll Control Act. Suspension Seat belt retractor Folding steering wheel Shift & Clutch Pumps Locks Compressors AD 1-5 steering AD 1-5 braking Advanced functions Enhanced sensing Cybersecurity 12V à 800V | 50W à 50kW | QM à ASIL-D Advanced Safety | Advanced Security | Value-added Functionality
  10. 10. © ZF Friedrichshafen AG © ZF Automotive UK Limited The Challenge October 14th, 2021 | Engage with .... ZF 10 ASPICE Safety: ISO26262 Cyber security: ISO21434 AUTOSAR Digital Twin Models 12V – 800V 50W – 50kW QM – ASIL-D Added Value Functions, e.g.: Condition monitoring Haptic Feed-back Wide range of products High Design Effort High Quality Advanced Safety Advanced Functionality Reusable Architecture reduces design effort across a platform Reusable Architecture helps to improve quality
  11. 11. © ZF Friedrichshafen AG © ZF Automotive UK Limited All Servodrives have the Same Basic Requirements Structure October 14th, 2021 | Engage with .... ZF 11 Typical Servodrive Requirements ASPICE level ISO26262 Cyber security / SOTA Blocked torque Excessive / reverse torque Insufficient / loss of torque Battery voltage Battery current limit Vehicle harness resistance Stall torque Max output power Torque control bandwidth Temperature Torque / Velocity / Position control Battery current export & control Export motor torque / position / velocity Thermal protection Under / over voltage protection Over current detection Export system state 2 Y Y ASIL-D ASIL-D QM…ASIL-D Torque QM Position: ASIL-D QM QM ASIL-B QM 12V 100A 10mW 5Nm 1kW 500Hz 80 °C General Hazards Features Performance / Environment Product B: Electric power Steering Product A: Active suspension 2 Y Y QM QM QM Velocity QM Velocity: QM QM QM QM QM 48V 80A 12mW 6Nm 3kW 800Hz 60 °C These are fictitious examples to illustrate the concept and do not relate to a specific ZF product
  12. 12. © ZF Automotive UK Limited Servodrive Foundation Model Architecture Requirements Digital Twin Increased efficiency Faster response Embed lessons Learnt Improved processes Improved ASPICE compliance Reuse requirements Solution: Servodrive Foundation Model Re-use of Software components Re-use of Electronic Libraries Re-use safety and security analysis October 14th, 2021 | Engage with .... ZF Reuse test cases Re-use Digital Twin Models
  13. 13. © ZF Friedrichshafen AG © ZF Automotive UK Limited Manage Multiple Architectures October 14th, 2021 | Engage with .... ZF 13 The Servodrive Foundation Model must be able to handle Multiple sub-Architectures in one model Veh. power supply Veh. power supply Veh. power supply Micro- processor Bridge driver Motor Angle sensor Veh. comms bus Micro- processor Bridge driver Motor lane 1 Angle sensor Veh. power supply Veh. comms bus Motor lane 2 Micro- processor Bridge driver Motor lane 1 Angle sensor Veh. power supply Veh. comms bus Bridge driver Motor lane 2 Micro- processor Veh. comms bus Angle sensor Isolator Bridge driver Veh. comms bus Veh. power supply Veh. comms bus Veh. power supply Veh. comms bus Veh. comms bus A B C
  14. 14. © ZF Friedrichshafen AG © ZF Automotive UK Limited Digital Twin and HiL October 14th, 2021 | Engage with .... ZF 14 Servodrive System Sub-systems Servodrive Foundation Architecture Servodrive Digital Twin Servodrive HiL ECU HiL Processor in the Loop ECU Architecture Software Architecture Model Based Production Code Motor Design ECU Design Cyber Security Software Design Motor Architecture Base Software Design Systems Architecture Digital Twin In-the-Loop Verification
  15. 15. © ZF Friedrichshafen AG © ZF Automotive UK Limited Quietness Understanding In E-drive Technology (QUIET) • Eighteen month DER collaborative project between ZF and Romax (now part of Hexagon) • Determine what needs to be simulated to better predict eMotor NVH, and how: • Close gaps in understanding what needs to be simulated to adequately predict eNVH • Find computationally and time efficient ways to do these simulations • Prove the simulation method: • Set-up the simulation model for a similar, but different eMotor and predict eNVH • Obtain test data • Corelate simulation with test data • Move from analysis to design • Understand and build on existing processes • Demonstrate the process can be used to achieve improvements in eNVH 15
  16. 16. © ZF Automotive UK Limited CAE model: Validated and understood Parallel rig and model build Simulation requirements identified Structural behaviour – from test Insight into system dynamic behaviour New software capability Best-practice methods Improved workflow and processes Knowledge gain Column drive Romax Evolve model Rack drive Romax Evolve model Electrom agnetic behaviour C o n t r o l + E l e c t r o n i c s + M o t o r QUIET: Improved Understanding through Simulation and Test QUIET DER project in collaboration with Romax Technology (part of Hexagon)
  17. 17. © ZF Automotive UK Limited QUIET: initial comparison of simulation and measurement Mode number Freq (Hz) Romax Evolve Freq (Hz) Modal results from test rig (ZF) 1 1320 1291 2 1961 1963 3 2344 2366 QUIET DER project in collaboration with Romax Technology (part of Hexagon)
  18. 18. © ZF Automotive UK Limited © ZF Automotive UK Limited Power electronics, machines and drives collaboration areas October 14th, 2021 | Engage with .... ZF 18 § Rotor containment and bearing technologies for high speed machines § Motor and electric drive topologies § Off-the-shelf 400-800 V inverters for prototyping § Additive manufacture of non-active motor components § Semiconductors with defined failure modes § Additive manufacture of copper coils § Prototype lamination production methods § Thermoplastics with improved cooling § Specialist simulation software, particularly for simulating some of the newer applications mentioned earlier § Condition monitoring and prognostics of motors § GaN/SiC drive circuits and power stages § Sealing systems for flooded motors
  19. 19. © ZF Automotive UK Limited © ZF Automotive UK Limited Thank you for your attention – questions? October 14th, 2021 | Engage with .... ZF 19 Phil Langley philip.langley@zf.com Strategic and business development Dr. David Moule david.moule@zf.com Technical Specialist – Electric Drives Dr. Connel Williams connel.williams@zf.com Srn Engineering Manager, Servo Drives Centre of Competence

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