Press Release

2019-Mar-29

ZF Test Systems presents at HMI 2019

  • ZF production test bench for 3rd generation electric drives
  • Data analytics increases product quality and reduces costs

Realizing cycle times from 90 seconds, optimizing data analytics and thus generating additional value for customers: These are the advantages offered by the Test Systems business unit of ZF with its new functional test bench for electric drives – for prototype construction as well as high-volume requirements. The test bench will be on display at the ZF booth in hall 25, booth C11.

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ZF Test Systems presents at HMI 2019

ZF functional test bench for electric drives

The increased use of electro mobility in cars requires new test benches for electric drives. They differ from conventional engine and transmission test benches mainly due to the high speeds of up to 23,000 rpm as well as the geometric characteristics of e-axles. The 3rd generation E-Mobility EOL test bench (Fig. 1) from ZF, presented at the HMI, fulfills all the requirements arising from the transition to electric mobility. Core components are the battery simulator for supplying the drive motor as well as two powerful drive modules with rated output of up to 200 kW and an axle torque of up to 10,000 Nm. The drive unit essentially consists of a water-cooled asynchronous motor, which is connected to the item being tested via a coupling and a drive pinion with toothed shaft. Acoustics (structure-borne noise and airborne noise), efficiency, maximum operating points and functions such as parking brake or oil pump are tested. In addition, an efficiency (WLTP) and high-voltage test are performed.

ZF offers functional test benches for electric drives for prototype construction as well as for high-volume applications. Cycle times from 90 seconds can be achieved here.

Data analytics

An improved and more effective evaluation of a product’s data during its life cycle can reduce costs while at the same time enhancing the quality of both the current product and its successor. This requires a linkage between the data from the fields of R+D, production, and EOL testing, as well as the evaluation of customer data (Fig. 2).

ZF Test Systems already performs data analytics for EOL testing and production. An important basis for this is the combination of different know-how areas from the ZF Group:

  • Production process know-how from transmission production for more than 100 years
  • Product know-how through countless applications in the areas of passenger cars, trucks and industrial technology
  • Test know-how from more than 1,300 delivered test benches in the R+D and production area
  • Applied data analytics know-how from topics such as autonomous operation, e.g. pattern recognition

ZF has the expertise to design superior data analytics methods and models to enable rapid results for the customer.

Data analytics 1

In the end-of-line test, a large amount of data is generated with regard to the tested item and the test bench. By evaluating these test data using big-data analysis and pattern recognition, the quality of the product can be increased and the testing process can be accelerated. Specifically, this means:

  • A significant reduction in the error rate of the product is achieved
  • The avoidance of test redundancies in the multi-stage manufacturing process leads to time savings
  • Through the automated determination of meaningful test limits, the complexity of the product and process can be better controlled and continuously optimized

Data analytics 2

Linking the data from the EOL test with the data generated during the production of a product can help to optimize the production process and thus reduce product costs.

  • By identifying influencing variables, the process can be optimized
  • Delivery capacity is increased by reducing the internal return rate
  • Targeted improvement measures lead to savings in time and materials

Data analytics 3

Here the data from the EOL test, from production and from development are combined and offer the potential for further optimization possibilities in the product and at the final development process e.g. by using digital twins.

  • A derivation of performance capability allows the definition of new variants without the need for 100% field tests
  • Achievement of time and cost savings
  • Added value is generated for product quality and processes

Data analytics 4

In the last step, the data from the operational phase of the product are integrated and thus have a positive influence on the subsequent generations of the product and the optimization of process steps.

  • For the development of the next product generation, this brings changed or optimized design requirements
  • In addition, the determination of real load collectives allows adapted service intervals (example: ZF TraXon Predictive Maintenance)
  • Targeted validation adjustment by using this operational data

ZF Test Systems

ZF Test Systems develops and produces test systems for on- and off-road mobility. As specialists for validation and development test facilities, we improve the quality of the driveline, active chassis, tires and wheels as well as brakes, thus contributing to enhanced safety and comfort for the driver.

CONTACT

Gernot Hein

Head of Communication & Public Affairs, Industrial Technology

+49 851 494-2480

gernot.hein@zf.com

Jan Hesselbarth

Marketing & Communications

+49 851 494-2703

jan.hesselbarth@zf.com