ZF has new motors with higher efficiency, cooler temps and less copper

[firsttruck]

ZF has new motors with higher efficiency, cooler temps and uses less copper

Also rotor looks star shaped like in Tesla's

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German (& international) auto/truck supplier ZF presents new drive series with higher efficiency and performance
Nov 22, 2022
https://www.electrive.com/2022/11/2...eries-with-higher-efficiency-and-performance/

.....
In the electric drive itself, the focus is on the cooling concept in order to increase the power density. In the stator, the copper rods of the braided winding technology developed by ZF have oil flowing directly around them – precisely at the point where most heat is generated during operation. With the more efficient cooling concept, it should be possible to increase the power with the same weight and installation space – or the electric drive becomes smaller and lighter with the same power. The braided winding technology is a further development of the ‘hairpin’ winding. This alone should reduce the required installation space by ten per cent, and less raw material is processed. All in all, ZF also wants to use less rare earth materials, which means that the electric motor can be produced more sustainably, according to the company.


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Using braided winding technology in the ‘hairpin’ winding reduces welds by 80%.

E-Motor Stator with new braided winding Innovation in components: ZF develops e-motors with new cooling concepts and new winding technology.

Smaller, lighter, more powerful: ZF presents new e-drives for passenger cars and commercial vehicles
2022-Nov-21
https://press.zf.com/press/en/releases/release_48003.html

.....
With a new, highly integrated e-motor, ZF once again increases the power density compared to the technology currently available in the market. A new cooling concept and a new winding technology play the decisive role here. Thanks to the new cooling concept, ZF allows oil to flow directly around the copper rods - exactly at the point where most heat is generated during operation. Such highly efficient cooling significantly increases performance with the same weight and installation space. The continuous power of the electric motor is increased to up to 85 percent of the peak power. In addition, the use of heavy rare earths can be largely dispensed with, and the e-motor can thus be produced more sustainably. The braided winding technology developed by ZF, a further development of the "hairpin" winding, enables a total of 10 percent less installation space. The winding head alone is around 50 percent smaller than with conventional approaches. This means that around 10 percent less raw material is processed.


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The puzzles for the best electric motors solved
https://www.zf.com/mobile/en/technologies/domains/electric_mobility/stories/electric_motors.html

 

[BillyGee]

Hopefully their can get those efficiency ratings at mass production numbers.

 

[Jhodgesatmb]

ZF has new motors with higher efficiency, cooler temps and uses less copper

Also rotor looks star shaped like in Tesla's

------------------------------------------

German (& international) auto/truck supplier ZF presents new drive series with higher efficiency and performance
Nov 22, 2022
https://www.electrive.com/2022/11/2...eries-with-higher-efficiency-and-performance/

.....
In the electric drive itself, the focus is on the cooling concept in order to increase the power density. In the stator, the copper rods of the braided winding technology developed by ZF have oil flowing directly around them – precisely at the point where most heat is generated during operation. With the more efficient cooling concept, it should be possible to increase the power with the same weight and installation space – or the electric drive becomes smaller and lighter with the same power. The braided winding technology is a further development of the ‘hairpin’ winding. This alone should reduce the required installation space by ten per cent, and less raw material is processed. All in all, ZF also wants to use less rare earth materials, which means that the electric motor can be produced more sustainably, according to the company.


------------------------------------------

Using braided winding technology in the ‘hairpin’ winding reduces welds by 80%.

E-Motor Stator with new braided winding Innovation in components: ZF develops e-motors with new cooling concepts and new winding technology.

Smaller, lighter, more powerful: ZF presents new e-drives for passenger cars and commercial vehicles
2022-Nov-21
https://press.zf.com/press/en/releases/release_48003.html

.....
With a new, highly integrated e-motor, ZF once again increases the power density compared to the technology currently available in the market. A new cooling concept and a new winding technology play the decisive role here. Thanks to the new cooling concept, ZF allows oil to flow directly around the copper rods - exactly at the point where most heat is generated during operation. Such highly efficient cooling significantly increases performance with the same weight and installation space. The continuous power of the electric motor is increased to up to 85 percent of the peak power. In addition, the use of heavy rare earths can be largely dispensed with, and the e-motor can thus be produced more sustainably. The braided winding technology developed by ZF, a further development of the "hairpin" winding, enables a total of 10 percent less installation space. The winding head alone is around 50 percent smaller than with conventional approaches. This means that around 10 percent less raw material is processed.


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The puzzles for the best electric motors solved
https://www.zf.com/mobile/en/technologies/domains/electric_mobility/stories/electric_motors.html

Is there a point to this story? Is Tesla using ZF motors in the Cybertruck? If not, who makes the machines that are making the Cybertruck motors?