Innovations of Great Value.

Driveline and Chassis Technology

for Cars

Driveline and Chassis Technology

ZF Friedrichshafen AGCorporate Headquarters88038 FriedrichshafenGermanyPhone +49 7541 77-0Fax +49 7541 77-908000www.zf.com

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Innovations of Great Value.Cars move people – both physically and emotionally. But it’s not just stun-ning design and powerful engines that fascinate people. There is also a great deal of interest in the more intelligent concepts that will make mobility and the thrill of the open road compatible with fuel and resource savings, and even more personal safety. These are by no means confl icting aims for ZF, which has been setting the pace in the fi eld of driveline and chassis technol-ogy for years and is a reliable partner to vehicle manufacturers when it comes to making driving more responsive, safer, and more effi cient.

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The Right Driveline for Every Need – Car Transmissions from ZF

These days, car transmissions are the true jacks-of-all-trades, backing up high-torque engines, improving fuel economy, and using fewer natural resources, while also contributing to a more dynamic and more comfortable drive. And they have to achieve all of this with-out taking up too much installation space in a wide range of vehicle models. ZF transmis-sions live up to these expectations and also set new standards. Every new generation of automatic transmissions reduces fuel consumption by between three and six percent. And what’s more, they can also boast other features such as direct engine integration, sporti-ness, precise gear shifting, comfortable handling, and a long lifespan.

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Transmissions

2 Mechatronics module: sensing your wishes through the soles of your feetThe mechatronics module unites the elec-tronic transmission control unit and the hydraulic shifting device as a single unit within the transmission. The electronic trans-mission control unit uses data relating to the driving conditions and behavior collected by sensors to ascertain when the driver would like to shift gears, which gear they need, and when would be the best moment to do so. The hydraulic shifting device is then respon-sible for implementing those changes.

1 Second-generation 6HP 6-speed automatic transmission: faster than human perceptionThe second-generation 6-speed automatic trans-mission is undoubtedly a fast transmission and is designed for torques of up to 850 Newton meters. At the heart of the transmission are the turbine-based torsional dampers for gasoline engines and a dual damper converter for diesel engines. They are able to bridge the converter slip period much quicker and therefore result in more direct engine integration for greater respon-siveness and optimized fuel consumption. In contrast to the predecessors, the gasoline engine reduces fuel consumption by three percent while the diesel engine saves six percent. A hydraulics system and control software now make it possible to downshift multiple times without any loss of time and also reduce reaction times by 50 percent to below the threshold of human perception.

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3 8HP 8-speed automatic transmission: designed for reduced fuel consumptionIncreased performance with lower fuel con-sumption: these seemingly contradictory exclusive targets have been achieved in ZF’s newly developed 8-speed automatic trans-mission. This has been made possible by a new transmission concept comprising four planetary gear sets and fi ve transmission

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clutches. And only two transmission clutches are unlocked per gear, thus resulting in great-er effi ciency and a higher overall transmission ratio. Thanks to its harmonious torque and speed distribution, the 8-speed automatic transmission doesn’t take up any more space than and does not consist of any more com-ponents than the latest 6-speed automatic transmission, but will nevertheless reduce

fuel consumption by six percent! This is also partly attributable to an early torque converter lockup, which is in turn also responsible for much more direct vehicle reactions when the driver pulls away. The 8-speed automatic transmission can also serve as a modular sys-tem for other initial acceleration, all-wheel drive, and hybrid concepts, without the need to adapt the basic concept.

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Transmissions

5 Dual clutch transmission: a sporty drive with low fuel consumptionWith up to 9,000 revs per minute and an effi cient transmission architecture, the dual clutch transmission really knows how to win over sporty drivers. Its winning feature comes from its two sub-transmissions: while the car drives with one of them, an electrohydraulic control system selects the next gear in the second sub-transmission. A wide array of highly effi cient transmission options reduces fuel consumption and emissions. A sponta-neous gear shift and an initial acceleration element that can be tuned to any type of engine round out the dual clutch transmis-sion’s sporty profi le.

6 6-speed manual transmission: powerful and comfortableThe 6-speed manual transmission was de-signed with powerful engines in mind and is able to transfer 600 Newton meters, making it more than suitable for modern diesel en-gines. Its top performance comes from its large range of gear ratios and fi ne gear inter-vals. The 6-speed manual transmission is particularly comfortable to use thanks to a precisely defi ned pressure point. What’s more, the oil does not need replacing at any point throughout the transmission’s lifespan.

7 eTronic automated transmission: economical and comfortableThe eTronic 6-speed automated transmission was designed for use in vans and minivans. It has a torque of between 350 and 500 Newton meters and helps save costs in the delivery business, as it takes care of choosing the gears and using the clutch and gearshift on behalf of the driver. The complex gear shifting strategy automatically chooses the most suit-able gear, regardless of the driver, the vehicle load, and the road. The driver nonetheless has the option of switching from automatic to manual and can then change gears using a touch control lever. Clutch operation remains automatic, thus eliminating any incorrect gear shifts that cause considerable wear.

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4 8-speed hybrid transmission: for twice the savings in the futureThe new 8-speed automatic transmission has a modular design that will allow it to be used in tandem with various drivelines without having to adapt the basic transmis-sion concept. It is particularly versatile when it comes to hybrids: a mild hybrid drive can be adapted with the addition of

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a crankshaft starter generator (a) or a full hybrid system can be integrated as a parallel hybrid drive (b) – both options regardless of the available space. Alternatively, the 8-speed automatic transmission can be combined with a hydrodynamic cooled clutch (c) or an integrated starting clutch (d). In terms of power take-off, it can be used with all stand- ard ZF all-wheel systems.

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Generating the necessary power for a car’s driveline is one thing – effi ciently transferring the engine power to the wheels is quite another. Depending on the driveline concept in question, the power is transferred between the engine and the drive wheels in different ways. ZF optimizes these channels with the help of innovative driveline technology such as dual damper converters, dual mass fl ywheels, hybrid modules, and intelligent distribu-tion of the drive torque via the Vector Drive rear axle drive, to make sure not an iota of power goes to waste. ZF driveline components have proven themselves to be robust, resis-tant to wear, and effective, meaning they are both economical and environmentally friendly.

Extracting Every Last Iota of Power –Driveline Components from ZF

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1 Vector Drive rear axle drive: intelligent torque distributionAs the drive torque is distributed to the left- or right-hand wheel individually, the Vector Drive rear axle drive generates an additional yaw moment. This “screwing motion” lends support to the vehicle steering and stabilizes the car during sudden swerving without having to apply any of the wheel brakes. Vector Drive therefore results in better driving

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dynamics and enhanced safety. And, with its planetary construction, the rear axle drive even delivers when the engine has no traction, i.e. in cases where the driver is not accelerating, such as when descending winding mountain roads. It also prevents tire slip when moving off on all kinds of road surfaces, which reduces wear and tear and improves the vehicle’s traction.

2 Power take-off unit: top performance in the smallest of installation spaces for cars with front transverse driveThe power take-off unit transfers the torque to the rear axle in all-wheel drives with front transverse drive and transmission. It is respon-sible for delivering maximum performance in a very tight space. The two-tier model with reinforced spur and bevel gears and a special housing construction admirably meets these requirements.

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3 3 Electric motor for hybrid drives: bringing the best of both worlds together intelligentlyHybrid drives are a high-performance cross between a combustion engine and an elec-tric motor that uses less fuel and generates fewer emissions. Whereas a combustion engine needs to reach higher speeds to achieve maximum performance, an electric motor is highly effi cient, delivering maximum torque right from the start. An intelligent drive management system utilizes the ad-vantages of both engine types for maximum driving performance in any situation, com-bined with reduced fuel consumption and emissions.

Driveline Components

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7 Shifttronic gearshift system: gear selection made easyThe gearshift is connected to the transmis-sion electronically, making it very reliable and easy to use. Another advantage of a purely electronic solution is that the gearshift commands can be combined with other electronic functions (e.g. in the chassis). A shift-by-wire solution also gives manu-facturers greater scope in designing and constructing the gearshift system.

8 Aggregate mounting: driving force for a smooth rideThe aggregate mounting can be switched on or off and is highly effective at preventing engine vibrations from being passed on to the bodywork. When the vehicle is idling, an integrated pneumatic suspension is activated to improve the comfort level. When the vehicle is traveling, however, the module au-tomatically switches to hydraulic suspension, which is more suited to a dynamic driving style. The aggregate mounting therefore balances out not only low-frequency engine vibrations when idling, but also high-frequency vibrations caused during driving. The module also prevents unwanted pitching from being passed from the road surface to the vehicle via the engine-transmission unit.

4 Clutch systems: reliable power transmissionModern clutch systems transfer the powerin vehicles with a manual transmissionand consist of a pressure plate, a clutch disk with friction linings, a torsional damper, and a clutch release bearing with a hydraulic actuator system. They are available with clutch diameters ranging from 160 to 280 millimeters and are tailor-made for a wide variety of different vehicles. They transfer input torque of between 80 and 600 Newton meters, have a high load-bearing capacity, and are extremely reliable. What’s more, with the XTend automatic wear compensation, clutch manipulation remains comfortable for the duration of its lifespan.

5 Torque converters: reduced consumption and maximum comfortTorque converters expertly counteract tor-sional vibrations to make driving vehicles with automatic transmission more dynamic and also to considerably reduce fuel con-sumption. Thanks to this torque converter trait, the transmission control unit is able to close the lockup clutch of the dual damper converter on diesel engines extremely quick-ly, thus reducing the time the vehicle is run in a consumption-heavy hydrodynamic state to a bare minimum.

6 Dual mass fl ywheel: for a quieter power trainThe dual mass fl ywheel is located between the engine and the transmission in cars with a manual transmission and is responsible for transferring the engine torque to the pressure plate and the clutch disk. Its main purpose is to balance out any torsional vibrations that are passed from the engine to the power train in order to rule out any growling or rumbling noises and to increase the level of comfort for the vehicle passengers. It also helps to reduce fuel consumption, as driv-ers of diesel engines without a dual mass fl ywheel in particular tend to drive at higher revs that cause less vibrations and sound more “acoustically pleasant.”

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Driveline Components

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Solutions that Take the Strain – Axle Systems from ZF

A lot is expected of car axle systems – they have to balance out potholes, washboards, and other road surface irregularities while still giving the driver a feeling of direct con-nection to the road. With such an important part to play, it’s the kinematics of the solu-tion that really count, so the axle system, damping, and other chassis components all have to complement one another perfectly. ZF is a true technical expert when it comes to car chassis solutions and has exceptional chassis manufacturing know-how. As a result, automobile manufacturers from around the world place their trust in ZF’s complete axle systems.

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1 Front and rear axle systems: perfectly in tune The character of a car is very much depend-ent on its chassis, the individual components of which need to be perfectly in tune with one another to achieve the best possible re-sult. A single model of SUV can be fi tted with any one of up to nearly 100 different axle variations, depending on the engine size, the maximum load, and the quality of the roads

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in the market for which the vehicle is being manufactured. This is because the front and rear axles determine the car’s handling, how comfortable it is, its responsiveness, and its safety standard. There are, however, other factors at work: wheel trunks, sensors, wheel suspension and guidance, cross members, stabilizers, springs and dampers all have their part to play in connecting the wheels to the bodywork too.

One of the smallest – but no less important – components within the entire system are the rubber-metal components, which serve as elastokinematic connectors that highly effec-tively absorb vibrations and sound. With its expertise and experience, ZF supplies auto-mobile manufacturers with chassis compo-nents and complete axle systems that are constantly improving the dynamics, comfort, and safety of the manufacturers’ cars.

2 Corner modules: individual parts working in tandemCorner modules bring together the entire wheel suspension, i.e. wheel trunks, mount-ings, control arms, dampers, and springs, and the brake system. Special wheel guidance for off-roaders makes the vehicles suitable for rough terrains. Innovative suspension joints and rubber-metal mountings contribute to long suspension travel, which results in maxi-mum off-road traction.

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Axle Systems

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Greater Intelligence – Chassis Components from ZF

A car’s wheel suspension and damping are responsible for a good level of road contact and for minimizing vibrations and noise. They increase a vehicle’s safety and infl uence its driving characteristics. ZF offers tried and tested modules in this fi eld. The Nivomat leveling system makes sure the car is driven at the right level, whatever it is transporting, making it safer to drive and reducing wear and tear. Driving is even safer with variable damping systems such as CDC. They adjust the damping power electronically within milli-seconds to the driving situation, between a hard, sporty damping feel and a soft, comfort-able one. Networking together with other units, CDC is part of an intelligent chassis that is capable of reacting to all sorts of different driving situations.

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1 CDC electronic damping system: uncompromising dampingCDC (Continuous Damping Control) adapts the chassis damping to the current driving situation on a precise sliding scale, thus mak-ing it easier for the driver to control the vehi-cle. Sensors pass on information about the road surface, vehicle behavior, and driver responses to the electronic control system, which then calculates just the right damping power for the driving conditions every two milliseconds. A proportional valve in the damper then sets each wheel at just the right damping level.

3 Nivomat leveling system: always doing its level bestThe Nivomat leveling system features special shock absorbers for the rear axle that keep the vehicle at a constant height regardless of the load and without any hydraulic or electri-cal connections. This is particularly important in vehicles which carry loads that vary in size or vehicles which have a trailer attached. Nivomat takes the energy it needs from the motion between the wheels and the body-work.

5 ARS Active Roll Stabilization: reduced rollWhen a vehicle takes a corner, actuators connected to hydraulic swivel motors on the stabilizer rod cause the two stabilizer halves to rotate towards each other, generating torsional torque. This helps reduce rolling on corners and can even cancel it out com-pletely when the transverse acceleration is below 0.3 g. As a result, the vehicle is easier to control and safer to drive.

6 AOS Adaptive Off-road Stabilizer: greater off-road traction As soon as you get off the open road, a rigid stabilizer rod can be more of a hindrance than a help, especially when it results in a wheel simply hanging in the air. AOS is a robust system that allows the driver to decouple the stabilizer rod to improve wheel-to-road contact.

7 SMiCA control arm: more functions, less weightNew manufacturing processes result in parts that are not only lighter, but also better. SMiCA (Sheet Metal integrated Control Arm) has an integrated suspension joint and is made without any rivets or screws, making it lighter than the average sheet metal control arm. It also takes up less space than more conventional solutions, giving designers greater scope when planning a chassis.

4 Ball joint sensor module: precise data for all control systemsThe wheel motion is monitored by a magnet inside the ball joint without any direct contact. Control systems can then use the high-resolution sensor data collated to regulate features such as the dynamic headlights, and to calculate the damping force required by the CDC electronic damping system or by pneumatic suspension systems.

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Chassis Components

2 Sensitive Damping Control mechanical damping system: for agility and comfortSensitive Damping Control is a mechanical damping system that makes cars comfort-able and safe on the road by distributing the damping between two consecutive pistons. The fi rst piston is attached to the piston rod, and the second is cushioned at the end of the rod between springs. This second piston, which has a separate characteristic curve, is not activated until the piston stroke in the fi rst valve has been “exhausted,” i.e. when the road surface is particularly uneven.

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Really Feel the Drive – Steering Technology from ZF*

Drivers have become accustomed to how easy steering can be. They benefi t from hydrau-lic and electric assistance which is supplied by the engine for simplifi ed steering. Today, good power-assisted steering is marked by its ability to give the driver a sense of direct responsiveness from their steering wheel: with immediate reaction and adapted steering support, depending on the speed and the driving situation. Even when the steering sys-tem serves as an active control system, as with superimposed steering systems. Intelligent energy management in power-assisted steering also contributes to reducing a vehicle’s fuel consumption and emissions.

*ZF Lenksysteme GmbH is a joint venture between ZF Friedrichshafen AG and Robert Bosch GmbH.

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1 Servolectric electric power steering system: greater functionality, less energy consumptionServolectric boasts a number of advantages. For a start, it only needs energy when the car is physically being steered. Depending on the vehicle type, this can cut energy consumption by up to 85 percent in comparison to hydraulic solutions, and this equates to a reduction in fuel consumption of 0.3 liters per 100 kilome-ters. It consists of a servo unit only, all other parts such as a steering valve, steering pump,

oil reservoir, and high-pressure tubes having been eliminated. It is consequently lighter and easier to install, while the absence of oil and hydraulics makes it absolutely mainte-nance-free. Just four basic Servolectric models are able to cover all vehicle classes, from compact cars to top-of-the-range models. And functioning completely independently of the vehicle’s engine, the servo unit can be easily adapted electronically to suit any kind of vehicle.

4 Active steering: driving enjoyment and safety An active steering system delivers a steering ratio that varies according to the driving situ-ation: it is sporty on winding roads, assisted in city traffi c, and provides added safety on the highway. What’s more, with active steer-ing, the driver can perform sudden evasive maneuvers more easily because the system automatically corrects the steering angle and stabilizes the vehicle.

5 Rack-and-pinion power steering system: precision and sensitivity The main advantages of ZF’s rack-and-pinion power steering system are extremely high steering precision on winding roads and a safer sense of steering at high speeds. With a variable-ratio rack-and-pinion power steering system, it takes the driver just two revolutions of the steering wheel to go from full left-hand to full right-hand lock. The speed-dependent version of this steering is known as Servotronic.

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Steering Systems

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2 Varioserv steering pump: the economical marvelThe Varioserv adjustable vane pump plays an important part in optimizing the energy usage of hydraulic steering systems. As their geomet-ric capacity can be adapted in accordance with the pump speed, less oil is pumped around and back through the low-pressure circuit. The result is energy savings of up to 50 percent and a reduction in fuel consumption of up to 0.15 liters per 100 kilometers.

3 Steering column: with memorized personal settingsElectrically adjustable steering columns do more than merely adjust the steering wheel to suit the driver’s preferences. An electronic control device can also memorize various steering wheel positions so that all it takes is the touch of a button when you get in the car to position the steering wheel exactly how you want it.

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Innovations of Great Value.There’s no such thing as a “typical” driver. Nor is there a typical car, and theautomobile market will increasingly be characterized by the wide variety of models and car types made available. But automotive development itself will continue to be characterized by certain objectives that have always been a main priority, and ZF’s innovative solutions will continue to address these objectives. Individualmobility needs to be economically viable and compatible with using naturalresources sparingly: ZF products generate fewer emissions and reduce a car’sfuel consumption. After all, driving a car should also offer added emotional valuewith improved driving dynamics and comfort. ZF products deliver on this front, with precision steering, quick and comfortable gear changes, and effective propul-sion. At the same time, ZF systems can also cater to high standards of active and passive passenger safety and make driving safer, either as a single unit or in tandem with other electronic control systems. It goes without saying that top quality, durability, and expert service are ZF standards.

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Conserving Resources

Every liter of fuel saved not only benefi ts the bank account of drivers, but greater fuel economy also benefi ts the environment. However, in order to com-ply with future CO2 specifi cations, more is required. Innovative technology and integrated networking of

ZF uses innovative technology to prove that greater mobility, com-fort, and driving dynamics can indeed be coupled with lower energy consumption, and ZF products are already reducing fuel consump-tion considerably today, along with CO2 emissions.

active ZF products in passenger cars can optimize energy usage.

Economical drivelines

The latest transmissions offer top performance, com-

on developing hybrid drives and is already in a posi-tion to offer the entire bandwidth from components to hybrid systems. The importance of hybrids to ZF is demonstrated by the 8-speed automatic transmis-sion generation of the future. It was designed to be able to be integrated into all hybrid systems, further reducing fuel consumption.

Lightweight

Reducing the weight of a vehicle reduces the amount of fuel the vehicle needs. The car’s weight can be reduced by using alternative materials such as aluminum and titanium as well as by employing innovative construction methods. Together, these

Conserving Resources

fort, and driving dynamics. And to keep up with the competition in terms of economy too, ZF’s engi-neers improved the energy effi cien-cy of ZF products and, as a result, fuel consumption has dropped by between eight and ten percent since 2001 with the help of the 6-speed automatic transmission. ZF is con-tinuing with this approach by devel-oping an 8-speed automatic trans-mission that will reap further fuel savings of six percent. At the same time, ZF is focusing more and more

Each new generation of auto-matic transmissions delivers greater performance, comfort, and economy with lower fuel consumption.

Automatic transmissions – easy on the environment and on your wallet

CO2 reduction using a sedan 3.0 l V6 (gasoline engine) as an example 188g/km200g/km

4-speed 5-speed 6-speedFirst generation

6-speedSecond generation

8-speedTransmission development

– 6%– 2%

– 5%

– 3%

– 6%

Fuel saved by development of ZF automatic transmissions

Based on: 3-speed automatic transmission

– 6%– 8%

– 13%

– 16%

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two approaches allow ZF to create transmission housings, chassis, and axle components that weigh less.

Energy phenomenon

It takes a lot of energy to permanently keep some-thing on standby, such as the oil pumps in hydraulic steering systems. That’s not the case with the Varioserv steering pump. Because it gets the job done with less oil, it uses up to 40 percent less energy than conventional hydraulic pumps, without

Electric motors for hybrid transmissions Automatic transmissions SMiCA control arms

Servolectric power steering systems Varioserv steering pumps

Origin of CO2 in cars

CO2 is not only generated by the combustion process in the engine. With economi-cal automatic transmissions, lightweight chassis, and energy-effi cient steering technology, ZF does its part to reduce CO2 emissions.

Servolectric electric power steering system for reduced CO2

A vehicle with Servolectric saves 0.3 liters per 100 kilometers. Assuming that 5 million Servolectric electric power steering systems have been produced so far and that each vehicle clocks up an aver-age mileage of 10,000 kilometers a year, this equates to an annual gasoline saving of 150 million liters.

With an average emission of 2.37 kilograms of CO2 per liter of gasoline, this results in a reduction in CO2 emissions of around 356 million kilograms a year.

Rolling resistance

Drag

Weight

Other losses: AC, electrical equipment, wheel mounts, steering system, etc.

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sacrifi cing comfort. The Servolectric power steering system goes even further, cutting the steering system’s energy needs by up to 85 percent in comparison to hydraulic solutions as it only uses energy when the car is actively being steered.

Conserving Resources

Example:An upper midrange car with auto-matic transmission (rear-wheel drive) and medium engine size (3-liter gasoline engine). Secondary condi-tions: MVEG driving cycle (European cycle for analysis of emissions and consumption on dynamometers).

Engine: Physical limita-tions of effi ciency (non-optimizable)

Friction, charge chang-ing, combustion process (optimizable)

Automatic transmission

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17%

13%

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Greater Driving Dynamics and Comfort

For drivers, clocking up mileage quickly is more than merely a question of time – it is also a question of perception. With ZF transmissions such as the second-generation 6-speed automatic transmission or the dual clutch transmission, the gears are shifted so quickly that they are barely perceptible for the

Driving ought to be enjoyable. But what people enjoy can be very subjective – depending on the driver and their mood, it can sometimes be the thrill of speed, and sometimes the relax-ation of a more leisurely drive that they are looking for. Driving dynamics and comfort are fl ip sides of the same coin. ZF’s products tap the full potential of drivelines and chassis.

passengers. The torque converter’s fast lockup means the car drives more smoothly, even with gear changes. Intelligent gearshift electronics adapt to different driving styles, practically second-guessing the driver’s next moves through the soles of their feet, be it a zippy over-taking maneuver or simply cruising through the city.

Extracting every last drop of power

For effective, dynamic propulsion, the power generated by a car must be transferred from the en-gine via the wheels to the road without any losses caused by slippage or tire squeal, for example. The concept of the Torque Vector System goes one step further, by optimally distributing the drive torque to exactly where it is needed for the specifi c driving situation. As all of the vehicle’s transmis-sions – automatic transmission, transfer case, front and rear axle drive – are linked electronically, the power can be distributed individually between the front and rear axle and between the different wheels on each axle.

Greater Driving Dynamics and Comfort

Open differential50 % / 50 %

Drive torque distribution to the front and rear axle

Longitudinal distribution as required0–50 % / 0–100 %

Individual wheel torque distribution0–100 % / 0–100 %

Modern all-wheel drive concepts such as ZF’s Torque Vector System do not distribute the drive torque infl exibly (50/50 percent), but react to each driving situation. The drive torque can be distributed fl exibly both between the front and rear axle as well as between the left- and right-hand drive wheels from 0 to 100 percent.

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Automatic transmissions Transfer casesVector Drive rear axle drives

The transverse distribution supports the steering and stabilizes the vehicle. Sporty drivers of all-wheel drives will noticeably feel this optimum power distri-bution whenever they take a corner or change lanes quickly – even if they do not accelerate. Cars with rear-wheel drive can also benefi t from this intelligent approach to distributing the drive torque.

Unrestricted dynamics

ZF is pushing back the boundaries of driving dynamics so that drivers can choose the way they

drive to suit them, be it sportily or with greater safety reserves. ZF engineers are already working on the next generation of controlled chassis, making sure their own units fi t seamlessly into the vehicle’s net-working environment, including brake and engine control intervention. This is particularly important in the case of IWD (Intelligent Wheel Dynamics), a concept in which a central control unit for the active steering, CDC electronic damping system, and Vector Drive rear axle drive makes corrections within the dynamic drive limits to improve the stability of the

vehicle in critical situations. As a result, sudden eva-sive maneuvers, which put a great strain on vehicle stability, are easier to handle.

ZF’s dynamic drive concepts do not mean you have to drive a vehicle permanently within the limit. Instead, they increase safety and offer dynamics wherever and whenever the driver wants them.

Planetary transmission

Bevel differential

Multi-disk clutch

Vector Drive rear axle drive

Cardan shaft

Electric servomotors

CDC electronic damping systems

It really comes into its own on corners, when the drive torque is spread unevenly between the two drive shafts by the electro-mechanically actuated multi-disk brake of the modulation transmission. The right- and left-hand wheels then ac-celerate at different speeds and the vehicle is given additional steering (yaw moment).

Active steering systems

Greater Driving Dynamics and Comfort

Assistance on corners from Vector Drive

Spreading the drive torque between the wheels on an axle generates additional steering. This can increase the amount of steering on corners in order to compen-sate for understeer (top picture). Alternatively, it can be used to prevent breakaway of the rear of the vehicle (bottom picture).

Oversteer control

Understeer control

Vector Drive correction

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Greater Safety

Car safety is constantly being improved and there are already a number of safety-related ZF prod-ucts that have made their mark on the automotive market, such as the electronic damping system CDC (Continuous Damping Control), active steering, and ARS (Active Roll Stabilization). You don’t have to

Regardless of the category of cars, one of the most im-portant objectives for car manufacturers continues to be vehicle safety when driving. As the leader in the fi eld of chassis technology, ZF will be one of the driving forces behind these developments in the future too.

drive a top-of-the-range car to experience the height-ened safety standards offered by ZF technologies, as many units such as CDC and active steering are now also available in compact and midrange cars. ZF also invests its energy in developing innovative compo-nents that make do without electronics, such as the

Nivomat leveling system and the “Sensitive Damping Control” mechanical damping system.

Integration is the name of the game

The main aspect of this safety systems trend contin-ues to be the electronics. This is because integrating the sensor systems, control software, and control technology of the individual units into a system that works together can result in critical driving situa-tions being identifi ed and corrected much quicker than can be expected of the driver. There is increas-ing demand for innovative, electronically controlled by-wire technologies to be networked and integrated into vehicles, so that, in the event of a critical situa-

Greater Safety

IWD: intelligent vehicles

Electronics have already been introduced to the ma-jority of units in a car, in-cluding the engine, trans-mission, chassis, dampers, brakes, and steering. All of these units can work more effectively when they work in conjunction with one an-other. Driving maneuvers, vehicle response, and envi-ronmental and traffi c infl u-ences are analyzed together so that control intervention is fi ne-tuned and coordinat-ed throughout all the units.

IWDcontrol

Dynamic drive sensors

Driver behavior

Engine and transmission

Suspension and damping

Chassis mounts

Brake

Steering

Road conditions/

Malfunctions Vehicle

Vehicle reaction

Vehicle reaction

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CDC electronic damping systems Nivomat leveling systems Active steering systems

tion, the unit that can address the issue most effec-tively is the fi rst to respond. With IWD (Intelligent Wheel Dynamics), the ZF transmission, damper, and steering units work together with other auxil-iary electronic parts to improve vehicle safety.

Safety at all times

But ZF’s safety products don’t just kick in when a crisis occurs – they operate to improve your drive at all times. For example, it doesn’t take a risky swerv-ing maneuver for IWD to improve a vehicle’s steer-

Nivomat: non-electronic intelligence

Nivomat is a simple yet ingenious damping system that prevents the rear axle of a loaded car from “sagging,” which could cause tire wear and increased fuel con-sumption. It also keeps the headlights and bumper at the correct levels. Nivomat works without any additional energy supply or electronics.

Electronic networking ARS roll stabilizers

ing – it is also activated when taking fast corners on a normal drive. The CDC and ARS electronic units prevent a vehicle from rocking when its load shifts, making for a smoother ride for the driver and pas-sengers alike, both in normal driving circumstances and in dicier situations.

Greater Safety

Nivomat: driving safely with a trailer

Vehicles pulling a trailer are more diffi cult to control, es-pecially in critical situations. The Nivomat damping sys-tem makes trailers markedly more stable and therefore safer to drive, whether changing lanes, overtaking, or driving on uneven road surfaces.

Without Nivomat

With NivomatForce effect during acceleration Force from load

Force effect during acceleration Force from load

Without Nivomat

With Nivomat

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The Foundations of Success

ZF develops and produces products serving the mo-bility of human beings and goods. Innovations in Driveline and Chassis Technology provide increased driving dynamics, safety, comfort, and economy as well as lower fuel consumption and emissions in the vehicles of the customers: By land, by sea, and in the air.

ZF’s main priority is to meet its customers’ needs by using leading technology, quality, and service; this is the key to strengthening the international market position. In addition to the benefi ts of component expertise, the customer profi ts from the Group’s sys-tem know-how.

ZF is a decentralized organization with divisions and business units. They are responsible for world-wide products, markets, and results and are run as profi t centers. These operational entities are gov-erned by strategic and fi nancial objectives.

ZF plays an active role in society and is continuously engaged in a dialog with the public and its employ-ees. The company promotes employees based on qualifi cation, performance, work ethics, and mobil-ity. The company assumes social and societal re-sponsibility. Environmental protection is a professed corporate objective.

ZF is a leading worldwide automotive supplier for Driveline and Chassis Technology.

With total sales of euro 11.7

billion in 2006 and 55,000

employees at 120 production

companies in 25 countries, ZF

is among the top fifteen

companies on the ranking list

of the largest automotive

suppliers worldwide.

Car Driveline TechnologyZF Getriebe GmbH

Commercial Vehicleand Special Driveline TechnologyZF Friedrichshafen AG

Off-Road Driveline Technology and Axle SystemsZF Passau GmbH

Marine Propulsion SystemsZF Padova S.p.A.

Aviation TechnologyZF Luftfahrttechnik GmbH

Aftermarket TradingZF Trading GmbH

Sales and Service OrganizationZF Friedrichshafen AG

Car Chassis TechnologyZF Lemförder GmbH

Rubber-Metal TechnologyZF Boge Elastmetall GmbH

Powertrain and Suspension ComponentsZF Sachs AG

Steering TechnologyZF Lenksysteme GmbH*

*Joint venture of ZF Friedrichshafen AG and Robert Bosch GmbH

Driveline and Chassis Technology

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46 47

Transmissions:

Manual and automatic transmissions for cars, CVs, and

special vehicles Dual clutch transmissions for cars

Hybrid systems for cars and CVs Synchronized

transaxles, powershift transmissions, as well as continu-

ously variable transmissions for tractors Hydrodynamic

and hydrostatic powershift transmissions for construction

machinery and lift trucks Electric drives for lift trucks

Surface drives for boats Transmissions for boats

and ships Drives for mixer, rail vehicles, and aircraft

Industrial drives Elevator gearboxes

Driveline Components:

Gearshift systems for cars and CVs Control systems

for CVs, off-road machinery, special vehicles, boats, and

ships Clutch systems, torque converters for cars, CVs,

off-road machinery, and special vehicles PTOs and

retarder systems for CVs and special vehicles Axle

drives, bevel gear sets, differentials, and powertrain

suspension systems for cars and CVs Clutches and

brakes for industrial engineering Propellers for boats

and ships

Axles:

Front and rear axle systems for cars and CVs Corner

modules for cars Axles and axle components for

off-road machinery

Chassis Components:

Damper modules and damping systems for cars, CVs,

rail vehicles, racing and motorcycles Tie rods, sta-

bilizers, stabilizer links, control arms, suspension joints,

leveling systems, and crash-absorption elements for cars

4-point links, wishbones, torque rods, tie rods, stabiliz-

ers, suspension joints, and cabin suspensions for CVs

Chassis mounts for cars, CVs, agricultural machinery,

rail vehicles, and industrial engineering Precision

plastics parts for cars and CVs

Steering Systems:

Mechanical steering systems, hydraulic, electro-

hydraulic, and electric power steering systems for cars

Hydraulic power steering systems and rear axle

steering systems for CVs and special vehicles Steering

pumps, steering columns, and steering accessories for

cars and CVs

Driveline Technology Chassis Technology

ZF is a partner to automotive industry around the world

Alfa Romeo Aston Martin Audi Bentley BMW Bugatti Buick Cadillac Chery Chevrolet Chrysler Citroën

Daewoo Dodge Ferrari Fiat Ford General Motors Holden Honda Hummer Hyundai Jaguar Jeep

Kia Lamborghini Lancia Land Rover Lincoln Maserati Maybach Mazda Mercedes-Benz Mercury Mini

Mitsubishi Nissan Opel Perodua Peugeot Pontiac Porsche Proton Renault Rolls-Royce Saab Samsung

Seat S ˇkoda Smart Ssangyong Toyota Vauxhall Volvo VW

ZF Product Program

6HP, eTronic, and IWD are registered trademarks of ZF Friedrichshafen AG. Shifttronic is a registered trademark of ZF Lemförder GmbH. ARS, CDC, Sensitive Damping Control, Nivomat, and XTend are registered trademarks of ZF Sachs AG. Servolectric, Servotronic, and Varioserv are registered trademarks of ZF Lenksysteme GmbH.