ZF-AVE 130 Presentation En

AVE 130 – Electric Portal Axle

TU – Axle & Transmission Systems for Bu ses & Coaches ZF Friedrichshafen AG

Agenda

1.

Electromobility – Framework Conditions

2.

E-Mobility in the City Bus

3. AVE AVE 130: System System Benefits 4. AVE AVE 130: Technology 5. AVE AVE 130: Customer Customer Value Value 6. AVE AVE 130: Applications

Agenda

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2.


3. AVE AVE 130: System System Benefits 4. AVE AVE 130: Technology 5. AVE AVE 130: Customer Customer Value Value 6. AVE AVE 130: Applications

Agenda

1.


2.


3. A AVE VE 130: System System Benefits 4. A AVE VE 130: Technology 5. A AVE VE 130: Customer Customer Value Value 6. A AVE VE 130: Applications

Product Strategy between Growth and Scarcity of Resources Challenges and conf lict ing t argets n o h i t t a w l u o p r o g P

Growth

c i h t m o w n o o r c g E

n o i t a z i n a b r U

Resources

e n e I n r c g r y e d a e s m i n a g n d

Energy

Raw materials

Water

r S e s c o a r u c i r t c y e o s f

r a d w e I n m m c r e a a n a t e d s r n f i i o a g l r s

Food g t n r e i s o m a p s u e r n l o c a r v n t I

a w E a m n e r e n v i r n a o e t n s l s

§

E-Mobility: Influencing Factors E-mobil ity is a market trend

ENVIRONMENTAL PROTECTION

PROFITABILITY Influencing factors E-mobility

LEGISLATION

E-Mobility in the Commercial Vehicle: Framework Conditions 2015

§

2020

Temporary dr iving bans for city centers

2025

2030

Zero-emission zones

Fleet CO2 emission Light commercial vehicles

Zero-emission cities

CO2 emission Commercial vehicles > 6 t

Strong increase in passenger car e-mobility Significant decrease in component prices Battery technology: improved power-to y weight ratio, range, costs g o l Fuel cell vehicles: o n H2 filling stations, passenger car volume production (2017), h c e Hydrogen as a source of energy Storage medium for renewable energy sources

T

Agenda

1.


2.


3. AVE 130: System Benefits 4. AVE 130: Technology 5. AVE 130: Customer Value 6. AVE 130: Applications

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

D

Conventional diesel engine

Serial/parallel/plug-in hybrid

D

Central motor

E

Wheel motors E

19xx

2015

2025

~2035

E-Mobility in the City Bus: Drive Solutions Electri c bus dr ive types

Central moto r + AV 133

AVE 130 wit h integrated w heel mot ors

E-Mobility in the City Bus Comparison of Solutions in the Markets

Central motor

Wheel motors by other manufacturers

ZF wheel motors AVE 130

System

+

+

+

Service network

0

-

+

Weight

-

-

+

Performance

+

-

+

Bus design

-

+

+

Standard components

+

-

+

Safety

-

-

+

Criterion

Agenda

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2.



ZF AVE 130 Electric Portal Axle System Scope AVE 130 system exp ans ion AVE 130 axle

Drive control (hardware & software)

ZF system supply

Torque control

Vehicle control (HCU)

Inverter (hardware & softw are) List of inverters released by ZF Inverter s uppliers

Vehicle operation strategy Battery management Auxiliary control and others

OEM

ZF AVE 130 Electric Portal Axle 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

ZF AVE 130 Electric Portal Axle Weight Weight advantage compared to a central motor 

Electric motors are integrated in the axle – No separate motor suspension is required – No motor mounting elements are required – No propeller shaft is required



Result: increased installation space and weight advantages

Weight advantage compared to other wheel motors 

Small, high-speed asynchronous motors



Lighter than permanent synchronous motors without transmission



Weight-optimized axle bridge and standard spring carrier

AVE 130

Total weight only 1 220 kg

More space in the interior

Possible weight reduction by up to 500 kg

ZF AVE 130 Electric Portal Axle Performance AVE 130: 400 V AC vs. wheel mot or s (by other m anufactur ers) 

Art ic ul ated bu s with 2 driven axles

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 – Reduced costs and weight

Art ic ul ated bu s with 1 driven axle

– Only one driven axle incl. power electronics Pusher

Puller

ZF AVE 130 Electric Portal Axle Bus Design Compared to the Central Motor Neither a separate motor nor a prop shaft are required 

Increased load capacity



More space in the bus, for example for – passengers/seats



The bus can also be implemented as a puller version with only one axle



Further improvement of low-floor design

– stowage compartments

– lower axle bridge

– additional batteries/units 

Optimized design in the interior of the bus



Better weight distribution

– no differential 

Different axle bridge lengths are possible



Same design for left and righthand drive

ZF AVE 130 Electric Portal Axle Use of Standard Components AVE 130 mou nt ing con di ti on s co mpar ed to AV 133 mou nt ing con di ti on s 

Identical interfaces make it possible to use – standard v-links and trailing links – standard spring carriers – standard air springs – standard dampers

AV 133

– standard rims and wheels 

Use of – identical disk brakes – identical wheel bearings



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

AVE 130

ZF AVE 130 Electric Portal Axle Towing Safety AVE 130 (asynchronous motor) 

Not safety-critical

Permanent synchronous motors 

It is necessary to short-circuit the motor or to lock and pull up the driven axle



Where applicable, the propshaft flange connection must be disconnected

– It is enough to turn off the voltage at the inverter. 

Low drag torques (only wheel motors)

– Otherwise high, dangerous voltages will be induced

Agenda

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2.



AVE 130 Electric Portal Axle Concept and System Elements Concept: hi gh-speed asynchronous motor in combi nation with 2 gear ratios 





1st step Ring gear portal with power split and input gear at the bottom

1st step 2nd step

2nd step Planetary drive with 4 planet gears All gears are helical toot hed for max. noise optimization

Essential system elements 

Asynchronous motors, water-cooled, recirculation cooling on the inside, "highly integrated" (the electric motor does not have its own housing) – Ppeak = 2 x 125 kW – Pcont. = 2 x 60 kW – nmax. = 11 000 rpm – ncont. = 10 300 rpm (80 km/h at 275/70 R 22.5)



Wheel head – Overall ratio 22.66 – Ring gear portal with power split (patented) with i = 3.895 and planet gear stage i = 5.818

AVE 130 Electric Portal Axle Characteristic Data of the Traction Motor Characteristic data for each ZF traction mot or

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

AVE 130 Electric Portal Axle Electric Interface Requirements Requirements conc erning the electric interfaces: traction motor – drive inverter

400 V AC

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 Vehic le data: 1x AVE 130 400 V AC GVW = 28.0 t f roll = 0.009 A = 6.3 sqm Cw = 0.55 r dyn = 0.466 m i = 22.660 Intermediate circ uit volt age 650 V DC Installed power: Fuel converter Generator power Energy accumulator

200 kW 200 kW 250 kW

Available traction power (DC): Fuel converter 151 kW Energy accumulator 200 kW Power requirements Auxiliaries (DC):

40 kW

Agenda

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AVE 130 Electric Portal Axle Advantages for the Vehicle Manufacturer 

Appl ic abl e fo r al l el ect ri c driv e co nc ept s 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 saving s – Integration of the electric motors in the axle – No separate motor suspension components – No propshaft



The comp lete AVE weigh s onl y 1 220 kg


Increased bus desig n 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 poin ts simi lar to th ose of the standard axle (AV 133)

AVE 130 Electric Portal Axle Advantages for Fleet Operators 

More space in the interior of t he 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

AVE 130 Electric Portal Axle Advantages for Fleet Operators 

Zero-emission driving



Smooth and continuous ly variable starting



Low-noise



Vibration-free driveline – No propeller shaft



Simple wh eel ch ange



Global service network

Agenda

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2.



AVE 130 Electric Portal Axle Flexible for any Drive System Suitable for all electri c energy sour ces 

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 dieselelectric hybrid applications



Fuel cell



Trolleybus (overhead contact line)

Battery Hybrid: fuel cell/ battery

Hybrid: dieselelectric/battery

Overhead contact line/ battery

Overhead contact line/ diesel-electric

AVE 130 Electric Portal Axle 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

Mühlheim

Munich

Stuttgart

Wuppertal

Beijing

Milan

Moscow

Rotterdam

Seoul

Switzerland

AVE 130 Electric Portal Axle History 

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



Since 2004 fur ther development of t he wheel hub drive – Increase of the power per wheel head to 125 k W – 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

ZF-AVE 130 Presentation En

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