ZF is a global technology company that supplies systems for passenger cars, commercial vehicles and industrial technology, enabling the next generation of mobility. ZF allows vehicles to see, think and act. In the four technology domains Vehicle Motion Control, Integrated Safety, Automated Driving, and Electric Mobility, ZF offers comprehensive solutions for established vehicle manufacturers and newly emerging transport and mobility service providers.

1. © ZF Automotive UK Limited
Driving the Electric Revolution
Engage with.... ZF
October 14th, 2021
Philip Langley | Dr. Connel Williams | Dr. David Moule

2. © ZF Friedrichshafen AG
© ZF Automotive UK Limited
ZF Group – Financial Overview 2020
October 14th, 2021 | Engage with .... ZF
EUR 32.6 billion
sales
153,522
employees
EUR 2.5 billion
Research &
Development
EUR 1.4 billion
investments in
property, plant,
and equipment
EUR 1.0 billion
adjusted EBIT
2
3.2%
adjusted
EBIT margin

3. © ZF Friedrichshafen AG
© ZF Automotive UK Limited
Key Figures – Research and Development
October 14th, 2021 | Engage with .... ZF 3
2.5
2.7
2.5
2.2
2017 2018 2019 2020
7.3%
6.7%
6.1%
7.7%
Research and Development Expenditure
in € billion / share of sales in %
Output Invention Disclosures, Products
and Product Applications
2,164
Invention Disclosures
133
New Products
579
Product Applications

4. © ZF Friedrichshafen AG
© ZF Automotive UK Limited
Sustainability Strategy – Measures to Achieve 2030 Targets
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ZF Plants Supply Chain Products
100% green electricity
all ZF Locations worldwide
90% steel from electric arc
furnace, in Europe with
DRI* from natural Gas
50% recycled material
in ZF products
>40% fully electrified
Powertrain
50% CO2 neutral
road transport
in ZF logistics network
Invest 3x more in energy
efficiency (+xx% efficiency
in 10 years)
Setting the course for a sustainable future

5. © ZF Automotive UK Limited 5
ZF in the UK
2020 sales from ZF UK:
€ 1.7 billion >2,800 staff
in UK as of end of 2020
Shirley ZF Hub UK
£xx m Investment in new
Tech Centre
9 locations
Pontypool, Peterlee, Birmingham, Solihull, Darlaston,
Nottingham, Wrexham, Shirley, Leeds
Divisions of ZF
operate in UK
7 of 9
~1,000 Engineers
in UK
∎
∎
∎ ∎
∎
∎
∎
∎
∎
∎
2020 – ZF Acquires Wabco
2014 – ZF
1999 – TRW
1996 – LucasVarity PLC
1860 – Joseph Lucas & Sons
Long UK Heritage
∎
October 14th, 2021 | Engage with .... ZF

6. © ZF Automotive UK Limited
ZF Hub UK: Our new home from October 2021
Innovation for Next Generation Mobility
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7. © ZF Friedrichshafen AG
© ZF Automotive UK Limited
Servo drives Centre of Competence
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8. © ZF Friedrichshafen AG
© ZF Automotive UK Limited
Servo drives Centre of Competence
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9. © ZF Friedrichshafen AG
© ZF Automotive UK Limited
Automated Driving
Vehicle Motion Control
Integrated Safety
Electric Mobility
Next Generation Mobility - Now
October 14th, 2021 | Engage with .... ZF 9
Steer by Wire
Brake by Wire
Rear steer
Elec. Roll Control
Act. Suspension
Seat belt
retractor
Folding steering
wheel
Shift & Clutch
Pumps
Locks
Compressors
AD 1-5 steering
AD 1-5 braking
Advanced
functions
Enhanced
sensing
Cybersecurity
12V à 800V | 50W à 50kW | QM à ASIL-D
Advanced Safety | Advanced Security | Value-added Functionality

10. © ZF Friedrichshafen AG
© ZF Automotive UK Limited
The Challenge
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ASPICE
Safety: ISO26262
Cyber security: ISO21434
AUTOSAR
Digital Twin Models
12V – 800V
50W – 50kW
QM – ASIL-D
Added Value Functions, e.g.:
Condition monitoring
Haptic Feed-back
Wide range of products
High Design
Effort
High Quality
Advanced
Safety
Advanced
Functionality
Reusable Architecture reduces design
effort across a platform
Reusable Architecture helps to
improve quality

11. © ZF Friedrichshafen AG
© ZF Automotive UK Limited
All Servodrives have the Same Basic Requirements Structure
October 14th, 2021 | Engage with .... ZF 11
Typical
Servodrive
Requirements
ASPICE level
ISO26262
Cyber security / SOTA
Blocked torque
Excessive / reverse torque
Insufficient / loss of torque
Battery voltage
Battery current limit
Vehicle harness resistance
Stall torque
Max output power
Torque control bandwidth
Temperature
Torque / Velocity / Position control
Battery current export & control
Export motor torque / position / velocity
Thermal protection
Under / over voltage protection
Over current detection
Export system state
2
Y
Y
ASIL-D
ASIL-D
QM…ASIL-D
Torque
QM
Position: ASIL-D
QM
QM
ASIL-B
QM
12V
100A
10mW
5Nm
1kW
500Hz
80 °C
General Hazards
Features
Performance /
Environment
Product B: Electric power Steering
Product A: Active suspension
2
Y
Y
QM
QM
QM
Velocity
QM
Velocity: QM
QM
QM
QM
QM
48V
80A
12mW
6Nm
3kW
800Hz
60 °C
These are fictitious examples to illustrate the concept
and do not relate to a specific ZF product

12. © ZF Automotive UK Limited
Servodrive
Foundation
Model
Architecture
Requirements
Digital Twin
Increased efficiency
Faster response
Embed lessons
Learnt
Improved processes
Improved ASPICE compliance
Reuse
requirements
Solution: Servodrive Foundation Model
Re-use of Software
components
Re-use of Electronic
Libraries
Re-use safety and
security analysis
October 14th, 2021 | Engage with .... ZF
Reuse test cases
Re-use Digital Twin
Models

13. © ZF Friedrichshafen AG
© ZF Automotive UK Limited
Manage Multiple Architectures
October 14th, 2021 | Engage with .... ZF 13
The Servodrive
Foundation
Model must be able
to handle Multiple
sub-Architectures
in one model
Veh. power
supply
Veh. power
supply
Veh. power
supply
Micro-
processor
Bridge
driver
Motor
Angle
sensor
Veh. comms
bus
Micro-
processor
Bridge
driver
Motor lane
1
Angle
sensor
Veh. power
supply
Veh. comms
bus
Motor lane
2
Micro-
processor
Bridge
driver
Motor lane
1
Angle
sensor
Veh. power
supply
Veh. comms
bus
Bridge
driver
Motor lane
2
Micro-
processor
Veh. comms
bus
Angle
sensor
Isolator
Bridge
driver
Veh. comms
bus
Veh. power
supply
Veh. comms
bus
Veh. power
supply
Veh. comms
bus
Veh. comms
bus
A
B
C

14. © ZF Friedrichshafen AG
© ZF Automotive UK Limited
Digital Twin and HiL
October 14th, 2021 | Engage with .... ZF 14
Servodrive
System
Sub-systems
Servodrive Foundation Architecture Servodrive Digital Twin Servodrive HiL
ECU HiL
Processor in the Loop
ECU
Architecture
Software
Architecture Model Based
Production Code
Motor
Design
ECU
Design
Cyber Security
Software Design
Motor
Architecture
Base Software
Design
Systems Architecture Digital Twin In-the-Loop Verification

15. © ZF Friedrichshafen AG
© ZF Automotive UK Limited
Quietness Understanding In E-drive Technology (QUIET)
• Eighteen month DER collaborative project between ZF and Romax (now part of Hexagon)
• Determine what needs to be simulated to better predict eMotor NVH, and how:
• Close gaps in understanding what needs to be simulated to adequately predict eNVH
• Find computationally and time efficient ways to do these simulations
• Prove the simulation method:
• Set-up the simulation model for a similar, but different eMotor and predict eNVH
• Obtain test data
• Corelate simulation with test data
• Move from analysis to design
• Understand and build on existing processes
• Demonstrate the process can be used to achieve improvements in eNVH
15

16. © ZF Automotive UK Limited
CAE model:
Validated and
understood
Parallel rig and
model build
Simulation
requirements
identified
Structural
behaviour –
from
test
Insight into system dynamic behaviour
New software capability
Best-practice methods
Improved workflow and processes
Knowledge
gain
Column drive Romax
Evolve model
Rack drive Romax
Evolve model
Electrom
agnetic
behaviour
C
o
n
t
r
o
l
+
E
l
e
c
t
r
o
n
i
c
s
+
M
o
t
o
r
QUIET: Improved Understanding through Simulation and Test
QUIET DER project in collaboration with Romax Technology (part of Hexagon)

17. © ZF Automotive UK Limited
QUIET: initial comparison of simulation and measurement
Mode
number
Freq
(Hz)
Romax Evolve Freq
(Hz)
Modal results from test
rig (ZF)
1 1320 1291
2 1961 1963
3 2344 2366
QUIET DER project in collaboration with Romax Technology (part of Hexagon)

18. © ZF Automotive UK Limited
© ZF Automotive UK Limited
Power electronics, machines and drives collaboration areas
October 14th, 2021 | Engage with .... ZF 18
§ Rotor containment and bearing technologies for high speed machines
§ Motor and electric drive topologies
§ Off-the-shelf 400-800 V inverters for prototyping
§ Additive manufacture of non-active motor components
§ Semiconductors with defined failure modes
§ Additive manufacture of copper coils
§ Prototype lamination production methods
§ Thermoplastics with improved cooling
§ Specialist simulation software, particularly for simulating some of the newer applications mentioned earlier
§ Condition monitoring and prognostics of motors
§ GaN/SiC drive circuits and power stages
§ Sealing systems for flooded motors

19. © ZF Automotive UK Limited
© ZF Automotive UK Limited
Thank you for your attention – questions?
October 14th, 2021 | Engage with .... ZF 19
Phil Langley
philip.langley@zf.com
Strategic and business development
Dr. David Moule
david.moule@zf.com
Technical Specialist – Electric Drives
Dr. Connel Williams
connel.williams@zf.com
Srn Engineering Manager, Servo Drives Centre of Competence