ZF is expanding its 800V testing capabilities by offering validation services to external organizations, allowing more next-generation mobility projects to benefit from this advanced technology. The facility is accredited nationally and internationally to work with tier-one suppliers and OEMs.
Adrian Mitcham, Head of Special Applications at ZF, stated, “OEMs are eager to utilize the advantages of 800V systems, but facilities capable of validating these higher-rated systems have been limited. With our cutting-edge EMC and climatic chambers on site, we aim to offer 800V validation services to a broader range of organizations, helping to bring these benefits to the wider mobility industry.”
Most electric vehicles currently operate on 400V systems, requiring around 20 minutes of charging to add 200 kilometers of range. In contrast, 800V systems can achieve the same range in half the time. The 800V architecture also offers efficiency improvements, such as lighter wiring, and when paired with Silicon Carbide MOSFETs, can deliver up to a 10% efficiency boost, potentially allowing for smaller batteries or enhanced driving range.
ZF has developed a modular and scalable inverter system that works with both 400V and 800V setups. The facility is now actively testing various applications, including truck and bus systems. ZF’s Commercial Vehicle Solutions (CVS) division recently validated a fuel cell air compressor and a Hydrogen Recirculation Blower for heavy-duty vehicles, both of which were showcased at the IAA Transportation 2024 event.
The 800V Test & Validation Lab, ZF’s first dedicated facility of its kind in the UK, spans 46 square meters and is equipped to handle anything from small modules to full E-drive truck axles. Designed with safety in mind, the lab includes features such as an interlocked door for secure operations and active discharge resistance to rapidly remove hazardous energy in emergencies. The infrastructure is also prepared for future needs, with power supplies capable of handling up to 1,500V DC at 45kW, with potential upgrades to 90kW.
ZF plans to make the facility available for academic research and is already supporting the Institution of Mechanical Engineers (IMechE) in training high-voltage engineers in the UK to work safely with advanced systems.
