Components and Systems for Cars Chassis Technology

7/27/2019 Components and Systems for Cars Chassis Technology

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Chassis Technology

Z

FFriedrichshafenAG-ChassisTechnology-09/2011

Driveline and Chassis Technology

Brands o ZF

ZF Friedrichshafen AG

49447 Lemrde

Germany

Phone +49 5474 60-0

Fax +49 5474 60-902000

www.z.com

Components andSystems or Cars


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2

The demands placed on suppliers in

the automotive sector are changing

dramatically. Increasingly, suppliers

are being called upon to integrate

components into complex systems a development task that can only

succeed on the basis o close part-

nerships with vehicle manuacturers.

The uture will bring continued de-

mands or reduced uel consumption,

emissions, weight and installation

space, along with enhanced comort,

saety, and driving dynamics. To meet

these goals, innovative products are

essential. ZF has taken on this re-

sponsibility, demonstrating expertisein generating multiunctional solu-

tions with its intelligent suspension

systems.

Contents

Chassis Technology

rom a Single Supplier Page 4

Lightweight Construction, Ideal Form Page 6

More Driving Dynamics and Comort Page 8

Saety even in Extreme Situation s Page 10

Fields o Expertise in Chassis Technology Page 12

Research and Development Page 14

On Site Worldwide Page 16

ZF Group Page 17

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Chassis Technologyrom a Single Supplier

The chassis is one o the most complex and most

important systems in a car. It determines the driv-

ing dynamics o t he car. Steering, wheel control,

bearing, damping, spring, stabilizer and brake sys-

tem all determine a vehicles character. Likewise,

the chassis controls the vehicles NVH (noise, vibra-

tion, harshness) behavior, ensuring that vibrations

and noise are not elt or heard in the vehicle while

driving. This improves occupant comort. It is very

important how the individual systems and compo-

ZF is a worldwide leading automotive supplier o driveline and chassistechnology. The Chassis Technology division unites the groups expertise

in chassis technology or passenger cars and light commercial vehicles.

nents harmonize with one another. This is precisely

where ZF comes in. Thanks to the Chassis Technol-

ogy divisions comprehensive know-how, the group

is able to oer customers complete chassis expertise

rom a single source.

With 7 development locations and over 50 produc-

tion sites throughout the world, ZFs Chassis Tech-

nology division is always within easy reach o its

customers.

Chassis Technology Division

Organizational Structure

4

Chassis Components

Chassis Technology Division

Suspension ball joints

Cross-axis joints

Tie rods

Stabilizer links

Control arms

Knuckles and Hubs

Rubber & Plastics

Rubber-Metal

technology

Chassis

Powertrain

Plastic technology

Vehicle saety

Chassis Systems

Front axles

Rear axles

Corner modules

Subrames

Active Kinematics

Control (AKC)

Suspension Technology

Active suspension

systems or

passenger cars

Conventional shock

absorbers or

passenger cars

This is necessary, too, because when ZF producescomplete axles or automobile manuacturers, they

are delivered to the manuacturers assembly lines

just-in-sequence. Close cooperation also brings the

best results when it comes to developing chassis.

Around the world, ZF enjoys excellent reputation

as outstanding development partner. To ensure that

this remains the case or chassis technology, the

division invested about 115 million euros in research

and development in 2010. There are a lot o chal-

lenges: mechatronics, or example, is making its way

into vehicle chassis and makes it possible to link the

chassis with other active systems. This improves con-

sumption gures and also boosts saety and driving

dynamics. Furthermore, new lightweight designs in

the chassis are already making a signicant contribu-

tion to an individual mobility that saves resources.

Chassis Technology Division 3,500 million euros

ZF Group 12,907 million euros

Chassis Technology Division 18,162 employees

ZF Group 64,600 employees

ZF Group Chassis Technology Division

Total revenue 2010

Employees 2010


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Lightweight Construction,Ideal Form

Less weight means lower uel consumption. And a

reduced proportion o unsprung mass or instance

in the chassis also improves driving dynamics.

Increasingly, alternative materials such as aluminum

or ber-plastic composites are being used in vehicle

chassis to achieve these double goals. But its not a

simple matter because these lighter materials demand

new chassis designs.

A study o a car rear axle with a wheel-guiding

transverse spring made o glass-ber-reinorced

With each new model generation, cars become saer, more com-ortable, and more dynamic but they also tend to get heavier.

The goal in the uture will be to reverse this spiraling weight.

Working with new materials and innovative designs, ZF makes

car chassis lighter.

plastic shows that ZF already has the expertise to

manuacture complete axle systems rom lightweight

materials. However, the weight saving o twelve to

teen percent compared with a conventional steel

rear axle is not t he only advantage. Also signicant

is the reduced complexity o the axle due to the

component integration, making installation by the

vehicle manuacturer much easier.

Whats more, when it comes to individual chassis

components, ZF also lets you shed the pounds:

The control arm requires no rivets or screw connec-tions. This makes it lighter than conventional sheet

metal control arms. Moreover, it requires less instal-

lation space and allows or more reedom when

designing the chassis.

A lightweight suspension strut wheel carrier moduleonly weighs hal as much as a conventional steel-

aluminum module. It is made o a mix o GRP, high-

strength steel, and aluminum. To compensate or

high bending stress, ZF engineers used an upside-

down design or the aluminum cylinder tube.

ZF lightweight components already in development

ZF applies this material mix and combination o all

lightweight construction options in volume produc-

tion, or instance, or pedals or lightweight dampers.

While the pedals make the most o plastics, light-

weight dampers eature tubes made o aluminum

and dierent wall thicknesses depending on load.

This makes production challenging because, ater all,

17 process stages have to be coordinated. Anothermature lightweight construction solution ready or

series production is the SMiCA (Sheet Metal inte-

grated Control Arm).

7

Aluminum damper

with plastic ring eye

Study o a GRP

wheel-guiding

transverse spring

Plastic pedal

module

SMiCA

Lightweight

suspension strut wheel

carrier module

90 %

Consumption

100 %

99 %

98 %

97 %

96 %

95 %

94 %

93 %

92 %

91 %

Reduction in vehicle mass

0 % 5 % 10 % 15 % 20 % 25 % 30 %

6

In compact vehicles

with innovative, eco-

nomical engines, it is

possible to save 4%uel by reducing the

vehicle mass by 10%.

New European Driving

Cycle (NEDC)

Real customer driving

cycle (AUTO MOTOR

UND SPORT lap)

Impact of vehicle weight on fuel consumption


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More Driving Dynamicsand Comort

AKC allows the track o both

back wheels to be regulated

actively and independently

or each wheel. This leads togreater driving stability at higher

speeds. Handling, agility and

driving enjoyment are improved

signicantly at normal speeds,

e.g. in city trac. A turning

circle reduced by up to 10%

increases maneuverability con-

siderably. Additional unctional

benets arise when AKC works

as part o a network o active

driving dynamic systems.

AKC Active Kinematics Control

Countersteering

improved agility

Self-steering

increased stability

Reduction of turning circle

improved handling

when parking/in city trac

8 9

Driving a car is supposed to be un, but ew things are as subjective as the enjoy-ment o driving. Depending on the type o person the driver is, and the mood he

or she is in, either high speed or gentle cruising may be un. Driving dynamics and

driving comort are two sides o the same coin. ZF products in the chassis release

a vehicles potential.

The chassis has many tasks: it bears loads, suspends,

dampens, steers, stabilizes and transers the drive

power to the wheels, and thus to the road. It also

prevents undesired noises and vibrations rom the

road rom entering the passenger compartment via

the bodywork. A system supplier such as ZF must

be able to do everything concerning the chassis.

We need to work in partnership with manuacturersduring development, oer them comprehensive so-

lutions or production and supply logistics and also

retain sight o drivers expectations. ZF can satisy

all these needs as a supplier o complete axle sys-

tems, chassis components and active systems.

Linking active chassis systems together oers new

levels o reedom with regard to driving saety, dyna-

mics and comort, without making compromises. An

example o this is the active damping system CDC(Continuous Damping Control). Even as a single

system, it increases comort, driving dynamics and

or prototype construction, rst tests, coordinationto validation and production. At the end o the day,

the intensive research and development work can

be noticeably elt by drivers and passengers who still

eel relaxed and comortable when they get out o

the car ater a long journey.

saety considerably. This eect is enhanced urtherwhen it works together with ARS roll stabilization

and the active kinematic adjustment system AKC.

Switchable engine mounts also improve driving

comort and dynamics by providing maximum isola-

tion rom structure-borne noise when the engine is

at idle and by damping vibrations when the vehicle

is moving.

With or without electronic assistance, sound

knowledge o axle and elastokinematics is needed

to design the optimum chassis. This knowledge can

determine the motion and distortion to the chassis

that can occur while driving and, i applied correct-

ly, can contribute to stable driving. ZF has mastered

the entire process chain o chassis development andtakes comort and driving dynamics into account

rom an early stage, rom design and calculationSwitchable

Engine Mount

CDC damper

with external valve

AKC

Ball joint with

integrated sensors

SDC Sensitive

Damping Control

Hydraulic

subrame mount


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Saetyeven in Extreme Situations

Cars are becoming saer all the time. And that is good. With slippery roads,bumps, and obstacles challenging drivers daily. With its wide product range,

ZF makes an important contribution to ensure sae driving everyday.

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Always stay grounded is the motto or saety in

road trafc. Drivers with optimum road contact

can cope better even with tricky situations such as

swerving at high speed. The chassis is decisive here

because the ront and rear axles determine the road-

holding and thereore the saety o a car.

Safety for all classes

From individual dampers to complete axles, ZF

supplies chassis components and systems or all

classes worldwide. The automotive supplier groups

core competence is know-how in the ne-tuning o

all chassis parts. One highlight is t he CDC electronic

damping system: Using data rom sensors, it seam-

lessly and precisely adjusts the chassis damping to

each driving situation individually or each wheel

and in ractions o a second. This not only prevents

pitching or rolling in t hreshold areas, but is also

very comortable or passengers. The CDC4 is avail-able or all our wheels, while the CDC 1XL (one

axle) is or the rear axle alone and is an economical

alternative above all or small cars.

This protects occupants rom injury and reducesthe repair eorts and costs, particularly as a result

o rear-end collisions in start/stop trafc.

A common problem with a ully loaded trunk isa sensitive rear-end due to the one-sided weight

distribution.

Components without electronics

The Nivomat leveling system works entirely with-

out electronics: it ensures that loaded passenger

cars always maintain the correct height and that

there is no sinking above the rear axle. This pre-

vents sluggish handling or, indeed, damper perora-

tion. Car/trailer combinations are also much more

stable which is a plus when changing lanes, over-

taking or when driving in bad road conditions.

The MCT (Multi Compliance Twist Beam) Axle

unites the benets o twist beam and multi-linkaxles. ZF also has t he right products or passive

saety: so called crash tubes absorb impact energy

through deormation.

CDC damper

with internal valve

SDC Sensitive

Damping Control

Nivomat

leveling system

Crash tube

MCT axle

CDC is an electronic damping

system that noticeably increases

driving saety, comort, and

dynamics by adjusting dam-ping orces optimally or each

individual wheel. A control unit

calculates the requisite damping

orces within milliseconds, and

adjusts the dampers just as

quickly.

CDC

Continuous Damping Control

CDC damper CDC damper

CDC damperCDC damper

Wheel acceleration sensor

Wheel acceleration sensor

ECU with body

acceleration sensors


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Fields o Expertisein Chassis Technology


Chassis Components

Chassis Systems

Rubber & Plastics

Monotube damper

Twin-tube damper

Suspension strut

Suspension strut module

Pre-loaded valve technology

Vario Stroke-dependent damping

Sensitive Damping Control

Nivomat leveling system

CDC Continuous Damping Control

ARS roll stabilization

Suspension ball joints

Cross-axis joints

Tie rods

Stabilizer links

Control arms

Knuckles and Hubs

Front axles

Rear axles

Corner modules

Subrames

Active Kinematics Control (AKC)

Suspension strut mounts

Subrame mounts

Conventional/hydraulic suspension link mounts

Stabilizer bar bushings

Powertrain suspension systems

Switchable and active engine mounts

Dierential mounts

Plastic pedal modules

Oil pans

Airbag housings

Plastic gearshit components

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Selected production volumes

Product Annual production

Axle systems > 1,500,000

Shock absorbers > 55,000,000

NVH components > 200,000,000

Ball joints > 150,000,000

Precision plastic parts > 220,000,000


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The ZF Group benets rom an international network

o development centers: The main development

locations are Friedrichshaen, Dielingen, Passau,

Schweinurt, Schwbisch Gmnd, Northville near

Detroit (USA), Pilsen (Czech Republic), and Shanghai

(China). Worldwide, approximately 5,400 engineers

work in Research and Development. Corporate R&D

coordinates and supports the activities at the develop-ment center in Tokyo (Japan). Every year, ZF invests

approximately ve percent o its sales in Research

and Development. With success, because innovative

products rom ZF set the standards or state-o-the-

art technology again and again. Development work

at ZF is organized according to decentralized and

central unctions. The divisions and business units

ocus on markets and product expertise, ensuring

customer-centered, competitive technological product

development.

Corporate R&D works with a strong emphasis on ba-

sic research and theory and supports the unctional

development areas in the divisions.

Research and Development

Innovations are not a purpose in themselves or ZF; they must pay

o, or manuacturers, feet owners, and drivers, but also or the

environment and society. Each new development must prove itsel

among the conficting priorities o these criteria.

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In the end, everyone rom the manuacturer to theend customer benets rom this approach.

Whether its a suspension strut or a complete axle

system, ZF always has its eye on all the details and

how they interact. This expertise in integration

turns optimally designed individual components

into comprehensively tested chassis systems with

great unctionality and a long service lie.

Customer focus as the key to our successThe development work o ZFs Chassis Technology

Division consistently ollows customer demand.

The most modern development tools guarantee and

optimum time-to-market solution. From simulation,

testing and coordination to series production, ZFs

decades o expertise have helped it to build up the

know-how or slender chassis development in ac-

cordance with customer specications. ZFs global

presence allows it to work cheek-to-jowl with vehicle

manuacturers.

ZF comes up with comprehensive concepts or

keeping people mobile today and tomorrow, rom

an idea to its implementation. As a reliable partner

o the automobile industry, the Chassis TechnologyDivision has a holistic approach to the development

process, rom the choice o materials to the mainte-

nance-riendliness o the nal products.

Four-poster rig

FE simulation

Load data

determination

Test drives

ADAMS simulation


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On Site Worldwide ZF Group

Worldwide, the ZF Group has 117 production companies and 8 main

development locations in 26 countries. In addition, we have approx.

34 service companies and representative oces as well as 650 service

partners. This enables ZF to provide a tight network o highly qualied

contacts close to international customers at all levels and in all regions.

ZF is a Worldwide Leading Automotive Supplier

o Driveline and Chassis Technology.

Powertrain Technology

Transmissions

Axle Drives

Powertrain Modules

Industrial Technology

Construction Machinery

Systems

Agricultural Machinery

Systems

Material Handling Systems

Test Systems

Special Driveline Technology

Electronic Systems

Marine Propulsion Systems

Aviation Technology

Wind Power Technology

Chassis Technology

Chassis Systems

Chassis Components

Rubber & Plastics


CV Technology

Truck & Van Driveline

Technology

Bus Driveline Technology

CV Axle Systems

CV Chassis Modules

CV Damper Technology

CV Powertrain Modules

ZF Lenksysteme GmbHis a joint venture oZF Friedrichshaen AGand Robert Bosch GmbH.

Steering Systems

Passenger Car

Steering Systems

Commercial Vehicle

Steering Systems

Passenger Car

Steering Columns

Global Atermarket

ZF Services

Brands o ZF

Driveline and Chassis Technology

ZF is consistently expanding its

global market presence. Both estab-

lished market regions and new

markets play very important roles.

Particularly activities outside Eu-

rope will gain more importance in

the uture. This applies not only to

the established markets in Northand South America, but especially

to the Asia-Pacic region and t he new markets in

Eastern Europe and India. Key aspects here are

market development through adapting products

to specic market requirements and best-cost-

country considerations which play a decisive role

in production and procurement. ZF supports the

international expansion o established customers

while also adding partners rom new market regionsto its customer portolio.

We develop and manuacture innovative, high-qual-

ity products and related technologies that improve

the mobility o people and goods. Our products

and services o er our customers clear added value

through leading technologies, quality, and service.

Our passionate commitment to achieving greater

efciency and resource conservation has made us

a trendsetter in new markets.


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Components and Systems for Cars Chassis Technology

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