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© ZF Friedrichshafen AG, 20141 2015-04-22 Lightweight @ ZF Friedrichshafen AG, Public
ZF Friedrichshafen AG
Derek Zhu, Head of Engineering, Chassis Systems
Lightweight @ ZF Friedrichshafen AG
© ZF Friedrichshafen AG, 20142 2015-04-22 Lightweight @ ZF Friedrichshafen AG, Public
Agenda
1.
2.
3.
4.
5.
6.
7.
The Need for Lightweight Design
Hybrid Brake Pedal
Composite Leaf Spring Axle
Innovation as a Whole System
ZF Lightweight Design Capabilities
ZF Friedrichshafen AG
Retrospective
© ZF Friedrichshafen AG, 20143 2015-04-22 Lightweight @ ZF Friedrichshafen AG, Public
ZF GroupKey Figures 2014
ZF-Konzern im ÜberblickThe ZF Group – An Overview
2014 2014 / 2013*
Sales € 18.4 billion + 9 %
Employees (end of year) ** 71,402 + 5 %
Capital expenditure € 1 billion + 5 %
R&D expenditure € 891 million + 7 %
113 production companies in 26 countries
7 main development locations in 4 countries
33 service companies and more than 650 service partners
**Without employees of the Rubber & Plastics business unit and without AIBC employees.
.
*excluding ZF Lenksysteme.
© ZF Friedrichshafen AG, 20144 2015-04-22 Lightweight @ ZF Friedrichshafen AG, Public
OrganizationStatus: January 2015
CEO
Corporate MarketCorporate R&D
Corporate Finance, IT, M&A
Corporate Human
Resources Corporate Governance
Corporate Production
Corporate Materials
Management
Corporate Quality
Electronic Systems
ZF Services
Car PowertrainTechnology
Car ChassisTechnology
Commercial Vehicle Technology
IndustrialTechnology
Automatic
Transmissions
Manual
Transmissions /
Dual Clutch
Transmissions
Axle Drives
Powertrain
Modules
Electric Drive
Technology
Die Casting
Technology
Chassis Systems
Chassis
Components
Suspension
Technology
Truck & Van
Driveline
Technology
Axle & Transmission Systems for Buses & Coaches
CV Chassis
Modules
CV Damper
Technology
CV Powertrain
Modules
Off-Highway
Systems
Test Systems
Special Driveline
Technology
Marine Propulsion
Systems
Aviation
Technology
Wind Power
Technology
© ZF Friedrichshafen AG, 20145 2015-04-22 Lightweight @ ZF Friedrichshafen AG, Public
Car Chassis Technology Division
Car Chassis Technology Division
Finance / Controlling / IT
Human Resource
Production
Development
Quality
Materials Management
Market
� Suspension joints
� Cross-axis joints
� Tie rods
� Stabilizer links
� Control arms
� Wheel carriers and
hubs
� Front axles
� Rear axles
� Corner modules
� Active Kinematics
Control (AKC®)
� Active Systems
� Conventional
Dampers
Chassis Components Chassis SystemsSuspension TechnologyCorporate Functions
Division
© ZF Friedrichshafen AG, 20146 2015-04-22 Lightweight @ ZF Friedrichshafen AG, Public
Agenda
1.
2.
3.
4.
5.
6.
7.
The Need for Lightweight Design
Hybrid Brake Pedal
Composite Leaf Spring Axle
Innovation as a Whole System
ZF Lightweight Design Capabilities
ZF Friedrichshafen AG
Retrospective
© ZF Friedrichshafen AG, 20147 2015-04-22 Lightweight @ ZF Friedrichshafen AG, Public
Trends for the Future4 Main Topics
CONNECTEDEFFICIENT
ELECTRIFICATION LIGHTWEIGHT
© ZF Friedrichshafen AG, 20148 2015-04-22 Lightweight @ ZF Friedrichshafen AG, Public
Emission Laws vs. Passenger Car Weight
Increasing weight spiral
Due to additionalequipment
More stringent requirements
CO2reduction
Reduced weight
Thanks to newmaterials
Weight spiral reversal
Targeted, innovativematerial use
Change of vehicle weight1970-2006
e.g: VW Golf Weight1975-2013
Reduced CO2 emissions legislation (EU)
© ZF Friedrichshafen AG, 20149 2015-04-22 Lightweight @ ZF Friedrichshafen AG, Public
Fiber-Reinforced Plastic - FRP
Savings potential thanks to weight reduction of 100 kg
� Consumption: 0.3l/100km
� CO2 emissions: 7.5g/km CO2
� Weight reductions thanks to functional integration
� Material use according to weight through endless fibers
Source: Bond Laminates
© ZF Friedrichshafen AG, 201410 2015-04-22 Lightweight @ ZF Friedrichshafen AG, Public
Agenda
1.
2.
3.
4.
5.
6.
7.
The Need for Lightweight Design
Hybrid Brake Pedal
Composite Leaf Spring Axle
Innovation as a Whole System
ZF Lightweight Design Capabilities
ZF Friedrichshafen AG
Retrospective
© ZF Friedrichshafen AG, 201411 2015-04-22 Lightweight @ ZF Friedrichshafen AG, Public
Weight: 66 %
Steel insert: 60 %
Plastic: 40 %
Steel pedal
Weight: 100 %
Metal hybrid pedal FRP hybrid pedal
Hybrid Brake PedalContinuous Fiber Reinforced Composite
organo sheet tool injec. molding brake pedalinsert
Weight: ~ 50 %
GFRP insert: 23 %
Plastic: 77 %
© ZF Friedrichshafen AG, 201412 2015-04-22 Lightweight @ ZF Friedrichshafen AG, Public
Organo sheet tailoring, plasticizing T
herm
ofo
rmin
g &
In
jection m
old
ing
Component handling - fully automated
Granulate drying and loading
One-shot processThermoforming & injection molding
Process technology at ZF
Hybrid Brake Pedal Processing Techniques – One Shot Process
© ZF Friedrichshafen AG, 201413 2015-04-22 Lightweight @ ZF Friedrichshafen AG, Public
� Extended freedom of design with maximum
functionality
� Lower weight saves fuel
� Reduced manufacturing costs
Plastic Pedal Box
© ZF Friedrichshafen AG, 201414 2015-04-22 Lightweight @ ZF Friedrichshafen AG, Public
Agenda
1.
2.
3.
4.
5.
6.
7.
The Need for Lightweight Design
Hybrid Brake Pedal
Composite Leaf Spring Axle
Innovation as a Whole System
ZF Lightweight Design Capabilities
ZF Friedrichshafen AG
Retrospective
© ZF Friedrichshafen AG, 201415 2015-04-22 Lightweight @ ZF Friedrichshafen AG, Public
Composite Leaf Spring Axle
Product Description
� FRP leaf spring axle with wheel control, suspension spring and anti-roll bar function
� Integration functionality associated with reduction
of parts
Benefits
� 15 % weight reduction vs. 4-link suspension
� Optimal space as a result of reduction of parts
� Optimized driver performance vs.
twist beam
© ZF Friedrichshafen AG, 201416 2015-04-22 Lightweight @ ZF Friedrichshafen AG, Public
Composite Leaf Spring AxleFunctional Integration
Integration step 1
Integration step 2
Integration step 3
Integration step 4
Spring
Spring Anti-roll bar
Spring Wheel guidanceAnti-roll bar
Spring Wheel guidanceAnti-roll bar
Damper strut
Trailing link
Central bearing
Strut
Control arm
© ZF Friedrichshafen AG, 201417 2015-04-22 Lightweight @ ZF Friedrichshafen AG, Public
Composite Leaf Spring AxleFEM Simulation
Load Case Simulation
central bearingmount at knuckle
stress exposure of fiber
Load Case Simulation
© ZF Friedrichshafen AG, 201418 2015-04-22 Lightweight @ ZF Friedrichshafen AG, Public
Composite Leaf Spring Axle Testing Base Materials
Several test devices on lab and part level within ZF quality tests
� fiber volume percentage
� CT scanner
� ultrasonic sound
� etc.
Geometry tests
� dimensional
� tolerances
� distortion
� etc.
© ZF Friedrichshafen AG, 201419 2015-04-22 Lightweight @ ZF Friedrichshafen AG, Public
Agenda
1.
2.
3.
4.
5.
6.
7.
The Need for Lightweight Design
Hybrid Brake Pedal
Composite Leaf Spring Axle
Innovation as a Whole System
ZF Lightweight Design Capabilities
ZF Friedrichshafen AG
Retrospective
© ZF Friedrichshafen AG, 201420 2015-04-22 Lightweight @ ZF Friedrichshafen AG, Public
ZF Innovation Car
� E-mobility in combination with optimized suspension light weight
� Innovative e-drive
� Increased traveling range
� CO2 reduction
� Optimized driving performance
© ZF Friedrichshafen AG, 201421 2015-04-22 Lightweight @ ZF Friedrichshafen AG, Public
ZF Innovation CarCombination of Electric Drive and Lightweight Chassis
Lightweight suspension strut and knuckle module
� Innovative FRP design with closed surface
� Integration of damper strut and knuckle
� Usage of fiber-reinforced plastics
� Advantages for driving dynamics thanks to
reduction of unsprung masses
� Up to 40 % weight reduction
Lightweight damper
� Aluminum cylinder tube instead of steel tube
� Integration of bottom plate, ring eye
and rubber joint into one plastic joint assembly
� Up to 25 % weight reduction
© ZF Friedrichshafen AG, 201422 2015-04-22 Lightweight @ ZF Friedrichshafen AG, Public
Agenda
1.
2.
3.
4.
5.
6.
7.
The Need for Lightweight Design
Hybrid Brake Pedal
Composite Leaf Spring Axle
Innovation as a Whole System
ZF Lightweight Design Capabilities
ZF Friedrichshafen AG
Retrospective
© ZF Friedrichshafen AG, 201423 2015-04-22 Lightweight @ ZF Friedrichshafen AG, Public
Process TechnologyDielingen Plant + Schweinfurt Plant
Dielingen Plant
Thermoplastics
Process Technology
� Injection molding
� Insert technology
� Thermoforming
� One shot
� Handling
� Prototyping
� Small series
Schweinfurt Plant
Duroplastics
Process Technology
� RTM
� HP-RTM
� C-RTM
� Prepreg hot pressing
� Handling
� Preforming
� Cutter
© ZF Friedrichshafen AG, 201424 2015-04-22 Lightweight @ ZF Friedrichshafen AG, Public
Agenda
1.
2.
3.
4.
5.
6.
7.
The Need for Lightweight Design
Hybrid Brake Pedal
Composite Leaf Spring Axle
Innovation as a Whole System
ZF Lightweight Design Capabilities
ZF Friedrichshafen AG
Retrospective
© ZF Friedrichshafen AG, 201425 2015-04-22 Lightweight @ ZF Friedrichshafen AG, Public
Retrospective
EFFICIENTLIGHTWEIGHT
� Innovative combination of materials
� Integration of functions
� Usage of alternative materials (CRP and GRP)
� Integration of manufacturing steps
� Advantages for driving dynamics thanks to reduction of unsprung masses
© ZF Friedrichshafen AG, 201426 2015-04-22 Lightweight @ ZF Friedrichshafen AG, PublicZF Friedrichshafen AG behält sich sämtliche Rechte an den gezeigten technischen Informationen einschließlich der Rechte zur Hinterlegung von Schutzrechtsanmeldungen und an daraus entstehenden Schutzrechten im In- und Ausland vor.
ZF Friedrichshafen AG reserves all rights regarding the shown technical information including the right to file industrial property right applications and the industrial property rights resulting from these in Germany and abroad.
Thank you for your attention
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