The power electronics are no longer designed as a separate unit, but instead are fully integrated into the transmission housing without increasing the outer dimensions of the transmission. The modular construction system enables mild, full, and plug-in hybrid drives to achieve top performances between 24 and 160 kilowatts. ZF has now turned the tables by intelligently designing its new generation 8-speed automatic transmission for hybridization from the start. Traditionally, hybrid transmissions are built by taking an efficient automatic transmission and replacing the torque converter with an electric motor with a higher power density. This technology, known as the “hairpin technique,“ allows the copper fill level to be significantly increased, which has a decisive impact on the power density. This does not require a significant increase of the packaging size since ZF relies on a new generation of internally developed electric motors and uses welded copper rods instead of coiled copper wire. The maximum torque, which can be attained without actuating the internal combustion engine, is 450 newton meters, thus allowing for swift passing, even in e-mode. The electric motor has a maximum power of 160 kilowatts and a continuous output of 80 kilowatts. ZF has laid the foundation for this with the plug-in model of the new generation 8- speed automatic transmission. This is contingent on electric range and electric power, both of which must allow for driving in everyday traffic with battery power only. Nevertheless, a plug-in hybrid drive could considerably lower the engine‘s CO 2 emissions. ZF estimates that at least 70% of all new vehicles in 2030 will still have an internal combustion engine.
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