ZF’s New e-Drive Modular Electric Powertrain Coming in 2025

EVs are notoriously known for its much heavier weight compared to its petrol-powered counterpart. Much of its weight stems from the addition of battery packs, of which its mass is proportionate with the total capacity. EV parts manufacturers are now scrambling to create lighter, compact components to compensate for the heavy weight, as well as making more room to house bigger battery packs.

ZF, a world-renowned auto parts maker unveils its new and improved e-Drive modular electric motor system. More compact and lighter than their current EV powertrains, the new e-Drive powertrain is poised for launch in 2025 in both 400-Volt and 800-Volt configurations.

The e-drive system comprises more than just the electric motor itself. It includes the motor inverter, controllers, transmission and even its software. All these components must be optimised to not only improve its performance and efficiency, but also reduce size, weight and cost, without compromising on the noise, vibration and harshness (NVH) it produces.

Upgrades come in the form of a new coaxial reduction gearbox that uses two integrated planetary gears that generate multiple ratios depending on the need, while also doubling up as an integrated differential. This multi-speed transmission setup garners more efficiency, thus reducing the EV’s overall power consumption whilst also increasing its travel range.

Aside from the ‘gearbox’, the motor’s cooling system is also deemed for an upgrade. ZF claims the new oil-flow cooling system has improved the powertrain’s power density, which increases its continuous power rating to 85%, thus allowing the motor to further tap its true potential. In other words, the whole powertrain is more efficient than ever.

ZF tackles the motor size issue by introducing a new winding method for said motor. ZF’s proprietary unique braided winding technique will replace the conventional hairpin-style approach, providing more compact packaging, as well as boasting fewer welding points.

All in, this upgrade reduces the motor’s overall size by about 10% compared to current ones. Said 10% size reduction also translates to less expensive rare materials required to build the motor.

The gizmo update sees ZF developing new high-voltage DC-DC converters for fuel cell electric vehicles (FCEVs). A “discrete package technology” is also being developed as we speak (or write) that will power all of the e-Drive’s electronics system, now requiring fewer components than conventional power modules.

As mentioned, ZF’s new e-drive powertrain will come in both 400-Volt and 800-Volt versions in either synchronous or asynchronous motor types, with its power output ranging from 67 HP to 738 HP.

ZF’s next-gen e-Drive powertrain is poised to hit the EV market in 2025, which sees them fulfilling a total of US$26 billion (approx. RM114 billion) worth of backorders for said powertrain. Being a full-fledged Original Equipment Manufacturer (OEM) for top EV brands, ZF will less likely sell its EV powertrains to small-time manufacturers and enthusiasts alike.