Hybrid gearboxes ready for the road

By Colin Windell 

ZF is gearing up to begin supply of its hybrid-enabled gearbox for commercial vehicles as early as next year with DAF the first truckmaker to be getting the new units.

ZF to supply hybrid gearbox to DAF Trucks from next year

The swiftly moving change to hybrid and electric vehicles in the haulage and bus industries has accelerated the development programmes of ancilliary suppliers such gearbox manufacturer, ZF, which is soon to place its TraXon Hybrid unit in DAF trucks.

The TraXon Hybrid automated transmission system makes 40-ton trucks and coaches up to 7% more economical. An electric motor with an integrated transmission ratio – positioned between the combustion engine and transmission – supports a maximum 130 kW and 1 200 Nm output torque.

While the TraXon Hybrid works on long-distance travel parallel to the diesel drive, it can also function in the city center as well as when maneuvering around bus depots as a quiet stand-alone zero local emissions drive.

In generator mode, the hybrid module can supply power to other power units, for example, during refrigerated transports.

ZF is set up just as broadly and systematically for all-electric drives as it is for hybrids.

In case of the AxTrax AVE electric portal axle, which is in volume production for low-floor city buses, ZF relies on the concept of the integrated close-to-the-wheel drive. Both liquid-cooled asynchronous motors deliver 2 x 125 kW and 2 x 11 000 Nm that help it master very challenging urban topologies.

For the best-possible efficiency and high electric ranges, ZF is offering the AxTrax AVE in a networked system featuring fully integrated inverters and drive control. The electric portal axle covers series hybrids as well as all-electric drives, whether powered by battery, fuel cell or overhead contact line.

In addition, ZF is offering the CeTrax electric central drive for low-floor and high-floor buses. Generating up to 300 kW and 4 400 Nm, it is designed for challenging applications.

Thanks to the ‘Plug-and-Drive’ approach, the CeTrax can be integrated into existing vehicle platforms without having to make major modifications to the chassis, axles, statics or differentials. Electricity-driven versions of originally combustion-engine powered bus platforms can be converted with relative ease. The drive control and inverter are also included in the scope of delivery so that the manufacturer gets an optimally coordinated complete system regarding performance, efficiency and service life.

CeTrax lite is the more compact system variant for vans and light commercial vehicles up to 7,5 tons. Considering it generates 150 kW and 380 Nm, it only weighs 120 kg, including a single-speed transmission ratio.

For vehicles up to 19 tons, CeTrax mid is available: its two electric asynchronous traction motors installed in parallel positions supply 300 kW and 760 Nm that a two-stage powershift transmission transmits.

ZF is constantly advancing vehicle electrification and now offers the broadest range of hybrid and all-electric drive solutions for almost every vehicle segment.