ZF Reveals EVSys800 Electric Powertrain

German automotive component supplier ZF introduces an electric powertrain planned for production in 2026 in the EVbeat, a Porsche Taycan-based engineering concept rated at up to 3,818 lb.-ft. (5,176 Nm) of torque.

Called EVSys800, the modular powertrain is based on an 800V electric architecture and consists of an electric motor, gearbox and silicon carbide-based power electric system – all weighing 163 lbs. (74 kg) or some 88 lbs. (40 kg) less than ZF’s current 800V powertrain.

With patented “braided windings” for the motor stator, ZF claims continuous power of 276 hp, with a peak of up to 369 hp.

The company heavily focused on torque during development, according to Otmar Scharrer, head of development for Electric Drivetrain Systems at ZF. It is rated at up to 3,818 lb.-ft. at the rear axle of the road-going EVbeat engineering concept.

As well as being lighter than ZF’s existing powertrain, the EVSys800 is also 2.0 ins. (51 mm) narrower, owing to a more compact 2-speed reduction gearbox. Central to the more compact dimensions is the “braided windings,” (pictured, below left) which are claimed to enable a 10% reduction in space as well as a 10% reduction in copper required.

ZF E-Motor_Braided_Winding

“Our goal was to make this (powertrain) as compact and lightweight as possible while maintaining high driving dynamics and increasing efficiency in real-world operation,” says Scharrer. “In terms of torque density, we are at the top of the podium when we compare ourselves with e-drives for passenger cars currently available on the market.”

The EVSys800 electric motor is cooled by a new oil-based system directly around copper rods. ZF also says it has been conceived to go into production without the need for rare earth materials.

Further developments included in the new EVbeat engineering concept include a new 800V heat pump called TherMas that uses fluorine-free propane as a refrigerant. The software bundle controlling the new electric motor has been developed to draw information out of a ZF-based cloud. The company says its new software package can then anticipate the optimum operating temperatures for any journey entered into the navigation system based on driving profiles.