German transmission manufacturer ZF Friedrichshafen has improved on the electric motor design for EVs by putting the connection assembly inside the gearbox housing and adding an alternating current (AC) filter to it, according to a patent filing with the European Patent Office. The new design also features better sealing and is said to prevent leaks and moisture ingress.
Established Supplier
ZF is a leading transmission manufacturer and is known for its widely used eight-speed longitudinal torque converter automatic transmission in combustion engine vehicles. the company is also making strides in the electric mobility space, supplying a two-speed EV transmission to automakers like the VW Group and developing advanced integrated EV drive systems, like the one outlined in this patent.
Key Components and Innovations
ZF’s latest patent outlines a more cost-effective and efficient EV drive system, integrating several key components:
- Electric motor
- Power electronics unit
- Connection assembly (with an AC filter)
- Gearbox assembly
Distinguishing Features
What makes its new design unique is that the connection assembly, which sits between the power electronics and the stator winding, along with an alternating current (AC) filter, are all smartly packaged within the gearbox housing. Other distinguishing features include a tolerance-compensating design that ensures a close fit of all components, despite the expected manufacturing tolerance deviations. Fluid sealing is also improved, ensuring that the assembly remains leak-free and keeps out moisture. Last of all, the assembly is said to be built in such a way that it eases access for maintenance to simplify servicing.
Advancing EV Technology for Greater Efficiency
ZF’s innovative design enhances the characteristics that are most important in electric motor development, namely ease of maintenance, efficiency, and cost. By optimizing these aspects, the new system could reduce EV costs, improve driving range, and enhance long-term reliability, making electric vehicles more accessible and practical for a wider audience.
