ZF Thermal Tech Enhances EV Range by 10% with Innovative Thermal Management System

ZF Thermal Tech Enhances EV Range by 10%

Highly efficient thermal management systems have the potential to extend the range of battery-electric and plug-in hybrid vehicles without the necessity for pricier drivetrains or larger batteries. With its newly market-ready system called TherMaS, ZF showcases its comprehensive vehicle expertise in this promising development area. TherMaS is designed to be a highly integrated system that is lighter and more compact than its counterparts while also being more efficient and cost-effective.

The use of propane as a refrigerant significantly boosts cooling performance, leading to a more compact and lightweight system design. In testing, optimized thermal management and improved utilization of waste heat from the drivetrain resulted in an increased electric range of up to 10% in challenging winter conditions and even up to 30% under extreme scenarios—establishing new benchmarks for climate control functions.

So, how can more range be extracted from an electric vehicle’s battery charge? While many might suggest enhancing the efficiency of the electric motor or opting for larger, more expensive batteries, there are alternative solutions. A significant portion of electricity consumption stems from the heating and cooling demands of the vehicle’s interior and the electric drive, which vary based on weather and operational conditions. This is where thermal management systems come into play.

“The battery of an electric vehicle is particularly sensitive to its optimal operating temperature, thriving between 15 and 25°C,” explains Dr. Otmar Scharrer, Senior Vice President of R&D, Electrified Powertrain Technology at ZF. Ambient temperature greatly impacts the effective range of an electric vehicle; on extremely hot or cold days, the thermal management system is put under additional stress, resulting in higher power consumption that can nearly halve the available range. “Enhancing thermal management is advantageous for both manufacturers and drivers,” adds Scharrer. This realization drove ZF to advance its thermal management system, TherMaS, to market readiness.

Superior Performance with Less Complexity

In 2023, ZF initially introduced a concept study of a central thermal management system meant to regulate thermal processes for the drive, battery, and interior of a vehicle. “Since then, we have achieved significant technological advancements. With superior capabilities and an easy-to-integrate design, our customers can anticipate improved e-drivetrain performance and extended electric range without sacrificing comfort,” summarizes Scharrer.

TherMaS boasts cooling and heating capacities of at least 10 kW between -25°C and +35°C, ensuring the battery remains within its ideal operating range—while generating less noise and vibrations than existing benchmarks. ZF’s holistic approach distinguishes it from current alternatives; engineers have integrated all thermal management functions into a complete, independent subsystem, including the development of the company’s first in-house heat pump.

These innovations have proven fruitful: TherMaS is simpler, lighter, more efficient, and more cost-effective for customers compared to market alternatives. A standout feature of TherMaS is its compact, propane-based heat pump refrigeration circuit, which customizes the integration of various components based on temperature and heating/cooling needs. Additionally, two separately controllable cooling circuits circulate frost-protected water—one for the electric motor and the other for the power and charging electronics, including the battery. Thanks to propane’s superior cooling properties, ZF engineers have succeeded in designing smaller circuits while maintaining performance.

The overall complexity of the system has been minimized, particularly in the E/E architecture and control of the water and glycol circuits. A lighter, more compact housing benefits manufacturers by saving installation space and assembly time, while also reducing heat and cooling losses due to closer proximity to the cabin, enabling shorter lines. The high degree of integration also decreases expected maintenance efforts, thereby enhancing the cost-benefit ratio for car manufacturers.

Outstanding in Testing, Ready for Market

ZF has thoroughly tested TherMaS in a demonstration vehicle, where the system delivered up to ten percent more electric range in demanding winter conditions and even up to 30 percent more under extreme scenarios. TherMaS has also performed impressively in various real-world driving situations. The new thermal management system will be offered in three performance classes, catering to a wide array of applications and vehicle platforms. Automotive manufacturers have expressed significant interest and confirmed the prototype’s high level of maturity.

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