ZF highlights software integration for chassis and battery technology

ZF highlighted the opportunities to use its software to develop smarter, more connected and more efficient commercial vehicle technologies.

The company says that by integrating ZF software solutions with chassis technologies, vehicle performance and safety can be improved. It is also able to leverage its software expertise from other vehicle segments within the ZF Group to produce intelligent systems that can reduce the total cost of ownership.

ZF says its software solutions can help optimize electric vehicle range, traction control and more.

Braking and electric drive synergy program

Using the energy generated during vehicle deceleration to charge on-board batteries can effectively extend the range of an electric vehicle or reduce the size of the batteries needed.

See also: Regenerative braking recovers energy, resulting in benefits in total cost of ownership

ZF says its Braking and e-Drive Synergy program harmonizes the electric powertrain and braking functions to optimize energy recovery with full stability control that goes beyond current standards, resulting in increased efficiency, safety and comfort while reducing total cost of ownership.

The system works by combining the next-generation ZF electric drives, AxTrax 2 dual and CeTrax 2 dual, with the advanced mBSP XBS braking system to use the electric drive’s capabilities to act as a brake actuator and vice versa, in controlling acceleration and braking. In this way, the system maximizes energy recovery to charge the on-board batteries while driving, extending the vehicle’s range. The system provides “one-pedal” functionality, improving driving comfort, especially when maneuvering at low speeds, such as off-road vehicles or in city traffic.

The system also provides improved driving characteristics by optimising traction control functions, reducing tyre wear and improving vehicle performance and stability on slippery surfaces.

See also: ZF drives innovation in commercial vehicles to shape the future of transportation

Software brake resistor

ZF has developed a software solution that helps replace hardware like brake resistors in battery-powered electric vehicles. The new software feature can limit the maximum energy content of the battery in certain charging situations, ensuring that additional energy generated by regenerative braking can be stored in the vehicle’s batteries. The system uses location data to determine if it is being charged in an area where it is likely to be going down a steep slope, which could result in additional battery charging early in the journey. If so, it ensures that the battery saves capacity while charging to harvest energy. The algorithm ensures that 100% charge is reached during the descent.

In all other areas, the system allows the battery to be fully charged when connected. With this innovation, large, heavy and expensive brake resistors are no longer needed, and energy efficiency is maximized, with all energy available for propulsion. This solution saves around 150 kg of weight and increases the available space in the housing. The system shows how an intelligent, cloud-based server function can save costs and weight while improving efficiency and sustainability.