Press Release
Hybrid drive solutions from ZF: Electrified for all routes
- More flexibility for e-mobility: ZF further developments adapt to market dynamics
- Hybrid transmission concept 8HP evo with improved efficiency and performance
- More range, lower emissions: Range extenders make electrified mobility attractive for a broad group of buyers
Zweibrücken / Friedrichshafen. As the market for electrified passenger car drives evolves rapidly and hybrid solutions regain momentum, ZF is actively expanding its portfolio to meet growing demand and presents an advanced concept version of its successful 8-speed automatic transmission: the 8HP evo offers efficient and flexible performance for various hybrid platforms. Additional highlights are the new electric range extender systems, which can minimize the range anxiety associated with electric vehicles.
“The market environment for electromobility is characterized by dynamism and change – and will remain so in the long term. These facts require a significantly larger drive portfolio than five years ago," says Mathias Miedreich, member of the ZF Board of Management and responsible for the Electrified Powertrain Technology Division, ZF. "Manufacturers demand solutions to more strongly diversify model platforms. And ZF offers these solutions." The technology group already has a broad portfolio of expertise and products in this area, which is now being further strengthened. ZF is highlighting two hybrid technologies: 8HP evo, a concept for the advanced 8HP automatic transmission for hybrid passenger cars, and its electric range extender systems for battery-electric platforms.
8HP evo concept: successful transmission for the entire hybrid power spectrum
The 8-speed automatic transmission is one of ZF's most successful products. From the outset, the current generation was designed according to the modular principle to support both conventional combustion engines and hybrid models. With the 8HP evo concept, ZF has once again significantly improved the electrification and efficiency of the transmission. Improvements to the electric motors and power electronics are the main contributors to this – including software-side function updates that further exploit the potential. "The experience gained from our pure e-drive solution has been incorporated into these upgrades to our established benchmark product," sums up Dr. Otmar Scharrer, Senior Vice President R&D, Electrified Powertrain Technology, ZF.
In the plug-in hybrid (PHEV) configuration, for example, the maximum electrical output increases from 160 kW to 200 kW and the maximum electrical torque from 500 Nm to 600 Nm. The losses at the input shaft are reduced by around 28 percent. Depending on the vehicle model and battery installed, up to 10 percent additional range is possible.
Until now, the transmission was intended for use in 48 V mild hybrids (MHEV) and 400 V PHEV systems. With the 8HP evo, ZF now also has a dedicated solution for vehicles without an external charging option, so-called HEV platforms on a 400 V basis. These charge the battery via recuperation when braking or while driving with the combustion engine. Compared to previous MHEVs, they not only support the combustion engine when starting or accelerating but also enable electric driving without having to rely on a charging infrastructure. ZF is thus responding to the increased demand for this variant, particularly in the US market. "With the 8HP evo, we are therefore covering a broader spectrum of performance and modularity," says Scharrer.
Electric range extender systems: Boost for the electric range
Many potential buyers of purely electric vehicles still feel the so-called range anxiety. In these cases, range extenders can be a solution: a combustion engine generator that is coupled to an electric motor to generate energy for the vehicle battery and extend the range. This allows drivers to enjoy the benefits of electromobility without having to sacrifice the flexibility of a classic combustion engine or plug-in hybrid vehicle.
ZF is currently working on the next generation of these systems, the electric Range Extender (eRE) and the electric Range Extender plus (eRE+). Both variants are a highly integrated design that is flexible in terms of performance, electronics architecture, 400 volts or 800 volts and semiconductor type. The eRE combines an electric motor as a pure generator with an integrated inverter and a planetary gearbox. The system is controlled by ZF software. The eRE+ also has an intelligent clutch and a differential. This allows the electric motor to be used not only as a power generator, but also as an additional secondary drive, which enables manufacturers to temporarily use electric all-wheel drive without installing an additional electric motor. The power can be scaled for both models. "This modular platform approach allows us to respond to dynamic market and manufacturer requirements," says Scharrer.
Range extenders impress with lower additional costs, shorter development times, lower platform costs and simplified supply chain management. This makes the technology particularly interesting for manufacturers who are new to the market – and have little experience with traditional combustion powertrains. However, range extenders are also worthwhile for established manufacturers. They allow smaller (and therefore more economical) vehicle batteries to be installed and help to comply with emission limits for fleets. ZF is preparing the production of a first customer project for 2026.
Hybrid solutions from ZF: future-proof technology
With these hybrid solutions, ZF is supplementing its purely electric drive technologies. This puts the Group in a position to meet all market requirements, even with a slower transition to e-mobility. "Our customers can be sure: No matter what degree of electrification is desired – ZF makes the right systems for it," summarizes Scharrer.
