ZF Opens Pioneering 800V Test and Validation Laboratory in the UK to Propel Next-Generation Mobility

ZF Opens Pioneering 800V Test and Validation Laboratory in the UK to Propel Next-Generation Mobility

(IN BRIEF) ZF has inaugurated the UK’s first dedicated 800V Test and Validation Laboratory at its R&D hub in Solihull, aiming to enhance the development of next-generation electric vehicles (EVs). Partially funded by the Advanced Propulsion Centre (APC), this advanced facility offers crucial testing capabilities for hazardous voltage systems, enabling both ZF and external clients to transition to 800V architectures that improve EV efficiency and charging speeds. Designed to accommodate various vehicle components, the lab emphasizes safety and is equipped for scalable operations. Additionally, it will support academic projects, including high-voltage training for engineers in collaboration with the Institution of Mechanical Engineers (IMechE). ZF’s commitment to advancing 800V systems positions it as a leader in electric mobility solutions, with potential benefits including reduced charging times and enhanced overall vehicle performance.

(PRESS RELEASE) SOLIHULL, 14-Oct-2024 — /EuropaWire/ — ZF has officially inaugurated the UK’s first dedicated 800V Test and Validation Laboratory at its research and development hub near Solihull, aiming to accelerate the advancement of electric vehicles (EVs) with 800V architecture. This state-of-the-art facility, partially funded by the Advanced Propulsion Centre (APC), is poised to enhance the efficiency, charging capabilities, and overall performance of future EVs.

The new laboratory represents a significant milestone for ZF, offering specialized testing facilities for hazardous voltage (HV) systems that will support both the company and its clients in the rollout of this cutting-edge technology. The facility is also set to facilitate validation testing for third parties, allowing a broader range of automotive manufacturers and suppliers to reap the benefits of transitioning to 800V systems. With several national and international accreditations, ZF is well-positioned to collaborate with tier-one suppliers and original equipment manufacturers (OEMs).

“OEMs are eager to harness the advantages of 800V systems, yet the availability of facilities capable of validating these advanced systems has been limited,” stated Adrian Mitcham, Head of Special Applications at ZF. “Much like our renowned EMC and climatic testing chambers, we intend to extend our 800V validation services to external entities, ensuring that the entire mobility sector can take advantage of these innovations.”

While the majority of current EVs operate on 400V architectures, which require around 20 minutes to gain 200 kilometers of range, an 800V vehicle can achieve the same range in just half that time. The shift to 800V not only allows for quicker charging but also reduces wiring gauge, resulting in lighter components. When paired with Silicon Carbide MOSFETs, this advancement could yield efficiency gains of up to 10%, potentially leading to smaller battery sizes or enhanced driving ranges.

ZF has designed a scalable and modular inverter architecture to maximize adaptability across both 400V and 800V systems. One of the initial projects tested at this facility involves a new fuel cell air compressor developed for truck and bus applications by ZF’s Commercial Vehicle Solutions (CVS) division. Recently, the facility was utilized to validate a new Hydrogen Recirculation Blower, showcased at the IAA Transportation 2024.

The laboratory spans 46 square meters, accommodating anything from compact modules to a full E-drive truck axle. Constructed with safety as a top priority, the laboratory includes an interlocked, monitored door that forms a secure safety cell. Enhanced safety protocols, such as active discharge resistance for rapid energy removal in emergencies and optically isolated instrumentation access, have been implemented. The facility is also designed for future expansion, with infrastructure capable of supporting power supplies of up to 1,500V DC at 45kW, expandable to 90kW.

Moreover, ZF is committed to using this laboratory for academic initiatives, supporting the Institution of Mechanical Engineers (IMechE) in high-voltage training programs. This initiative aims to equip UK engineers with the necessary skills to work safely with advanced 800V systems.

About ZF
ZF is a global technology company supplying advanced mobility products and systems for passenger cars, commercial vehicles and industrial technology. Its comprehensive product range is primarily aimed at vehicle manufacturers, mobility providers and start-up companies in the fields of transportation and mobility. ZF
electrifies a wide range of vehicle types. With its products, the company contributes to reducing emissions, protecting the climate as well as enhancing safe mobility. Alongside the automotive sector – passenger cars and commercial vehicles – ZF also serves market segments such as construction and agricultural machinery, wind power, marine propulsion, rail drives and test systems.

With some 168,700 employees worldwide, ZF reported sales of €46.6 billion in fiscal year 2023. The company operates 162 production locations in 31 countries.

For further press information and photos, please visit: www.zf.com

Media Contact:

Rashmi Parkhi
Spokesperson EMEA (without Germany) and India
Tel: +49 7541 77-3397
rashmi.parkhi@zf.com

SOURCE: ZF Friedrichshafen AG