ZF has developed the High Revolution Drive, a compact three-in-one electric drive system capable of reaching speeds of up to 30,000 revolutions per minute (rpm). The system combines an electric motor, power electronics and transmission in an integrated design intended to reduce size and weight while maintaining power output.
The new drive is designed for passenger cars and builds on ZF’s modular SELECT platform. Its high-speed motor and two-stage transmission allow vehicle manufacturers to use a smaller motor while delivering the torque required at the wheels. At the same power output, higher motor speed reduces the torque required from the electric motor. Since torque is closely linked to rotor volume, this allows the motor to be made smaller and lighter. A two-stage spur gear transmission with a ratio of approximately 18:1 converts the high rotational speed into usable wheel torque.
The version presented by ZF delivers a peak output of 200 kW and peak wheel torque of 3,500 Nm. It is nearly 25% smaller and 25% lighter than a comparable SELECT drive operating at 18,000 rpm. The required magnet mass is reduced by 50%, helping lower material costs and dependence on critical supply chains. Despite the higher rotational speed and gear ratio, the system achieves an efficiency of nearly 93%, comparable to the existing SELECT system.
Thomas Meiser, Head of ZF’s E-Mobility Business Unit, said the drive was developed by coordinating the design of the motor, power electronics and transmission rather than optimising individual components separately. He said controlling noise and vibration while maintaining system reliability had been key development requirements.
ZF has used its experience in gear and transmission engineering to address the challenges associated with high-speed operation. The design considers the electric motor, gearing, bearings and gear-tooth geometry as an integrated system to manage noise, vibration and durability.
The High Revolution Drive is intended primarily for high-volume passenger cars with power requirements of approximately 150 to 200 kW. Its architecture can be adapted to different power ratings and supports both 400-volt and 800-volt vehicle platforms. The drive is being developed as a variant of ZF’s modular SELECT platform, allowing the company to use existing technologies and production approaches. This is intended to reduce development effort and give vehicle manufacturers flexibility when selecting drive configurations for new vehicle architectures.
ZF is a global technology company supplying systems and components for passenger cars, commercial vehicles and industrial applications. Its portfolio includes electric mobility systems, transmissions, chassis technology, safety systems and software-based solutions. The company develops technologies for conventional, hybrid and fully electric vehicles.
