ZF Friedrichshafen AG, a prominent automotive supplier for Driveline and Chassis Technology, unveiled its technological novelties at the IAA commercial vehicle show in Hannover.
TraXon, the new automatic transmission system for heavy commercial vehicles, the new IS 80 TF independent suspension for trucks, the AVE 130 electric portal axle and the 6-speed EcoLife automatic transmission for buses, and optimized steering systems by ZF Lenksysteme GmbH, were on display at the ZF stand.
The innovations are ready to meet the future requirements of the automotive industry and were fittingly presented under the company slogan, ‘The Future in Transportation’.
TraXon, the new benchmark
The ZF TraXon is an automatic transmission system for heavy trucks that meets the market requirements for a versatile, economic solution for a broader application range.
It is based on a compact basic transmission which was designed for torques of more than 3,200 newton meters and is the benchmark in terms of its spread of gear ratios and power-to-weight ratio, with the modular kit concept ensuring ultimate flexibility. Dr. Stefan Sommer, CEO, ZF, expects long-term success from the new automatic transmission system.
Says Dr. Sommer: “As a result of TraXon’s modular design, the customer can select tailor-made drive solutions from a modular transmission kit”.
The basic transmission can be combined with five different modules, for example with the dual clutch module and/or the hybrid module with powerful 120 kilowatts, both technologies being made available for the first time in the heavy commercial vehicle segment. ZF has specially developed the PreVision GPS shift strategy for the new transmission. By using GPS data and digital map material, the transmission control unit responds in an anticipatory manner while saving fuel: The system avoids unnecessary gear changes in relation to the respective topography.
Cutting-edge truck chassis technology
With the highly innovative rear twin-axle suspension, ZF impressively underscores its lightweight design expertise for the commercial vehicle chassis.
The new chassis demonstrates how the overall system becomes lighter thanks to the integration of functions for individual components and using an intelligent material mix.
In a study, ZF implemented a complete glass-fiber reinforced plastic (GRP) 4-point link which was previously a standard cast component, thus making the unit roughly 11 kg lighter.
Among the special highlights is the IS 80 TF front single wheel suspension for heavy trucks.
Due to its innovative design by which the steering knuckle support was completely eliminated, a considerable added value was generated for manufacturers and vehicle operators. This aspect is further underlined through excellent comfort and driving characteristics as well as significantly reduced fuel consumption.
A reduction in weight by around 40 kg was seen with the IS 80 TF when compared to the current, steering-guided air-spring rigid axle. To round it off, the space-saving design of the ZF chassis revolution perfectly matches the truck’s installation conditions, thus facilitating easy integration by manufacturers. Another important aspect is that, in total, the above stated savings compensate for the additional weight created with the auxiliary components needed to attain the EURO 6 standard level.
Efficient bus driveline technology
Local, zero-emission driving with lane-independent city buses is enabled by ZF with the AVE 130, the electrically driven low-floor axle.
On display was the volume production design of the electric portal axle that convinces with its electric motor performance of 2×120 kilowatts and the maximum axle load of 13 tons.
The ZF-EcoLife, the 6-speed automatic transmission for buses, not only helps save fuel in public passenger transport but also makes traffic much quieter. During the setting-off process, the EcoLife allows for a maximum speed reduction of about 700 revolutions per minute, thus reducing the noise level considerably, by up to 6.4 dB(A) to be precise, compared to conventional automatic transmissions.
In this application, the ZF-EcoLife makes efficient use of its six finely tuned gears and the TopoDyn Life shift program. There is also a hybrid version of the ZF-EcoLife which successfully shows off its starting and braking process strengths in inner city applications.
The new Servoline linear steering system by the ZF Lenksysteme GmbH – a joint venture of the companies ZF and Bosch, applies the rack-and-pinion power steering concept to commercial vehicles. The short, compact design saves space and supports large steering angles. The adjustable Varioserv vane cell pump lives up to the reinforced demand for highly efficient, hydraulic steering pumps and since it displaces the truly required oil volume only, it enables energy savings of up to 40 per cent, thereby reducing the overall truck’s fuel consumption by approximately 0.2 liters per 100 kg.