Electrification of the Drivetrain with ZF: ZF-TERRA+

• Powerful generator system ZF-TERRA+ integrated into the ZF-TERRAMATIC transmission

The integrated generator solution: ZF-TERRA+

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The system ZF-TERRA+ (Fig. 17) comprises a powerful electric generator which is integrated into the transmission housing.

When operated in generator mode, ZF-TERRA+ serves as a powerful power source for electric loads. Up to 5% in fuel savings can be achieved through a power on demand operation of electrified auxiliaries on the tractor. Hence, also CO2 emissions can be reduced together with a boosted productivity and tractive effort. The ZF-TERRA+-system can be operated permanently in a generator mode to provide electrical output from 60kW.

If applied as power source to electric drives on the implement, the ZF-TERRA+-system can yield fuel savings and increased available power up to 5-10% on the tractor through better efficiency when compared to conventional e.g. hydraulic drives.

In addition, the electrification on the implement enables new design concepts on the implement through its flexibility in the arrangement and installation of drives.

If extended by an energy storage unit e.g. a hybrid battery, the ZF-TERRA+ -system can be converted to a powerful parallel mild hybrid system. This extension enables typical hybrid functions such as stop/start with powered auxiliaries, short term boost of the engine and stabilization and smoothing of engine operation. Especially for an intelligent power management of vehicle auxiliaries and electric drives on an implement, the extension of the generator system to a hybrid system creates additional degrees of freedom, which can be utilized for further improvements of fuel consumption, exhaust emissions and performance, when used in combination with an intelligent power management.

ZF-TERRA+ is integrated into the transmission and has, depending on the application, a neutral installation space. This enables easy integration of e.g. a separating clutch to decouple the generator/hybrid module from the engine for extended functionalities such as utilized in a full hybrid. Furthermore, an easy integration of a planetary gearset for increased power output is thus also possible.

For manufacturers of agricultural machinery ZF supplies complete and single source solutions for electrification systems. This comprises, apart from single components, also a power management control. This control optimizes the integrated operation of generator, combustion engine and electric auxiliaries in such a way as to avoid operational states of the powertrain with low efficiency and high exhaust emissions. The optimal matching of transmission shift or control strategy and power management, as provided by ZF, is a core competence in the market of electrified drivetrains. The strategy has direct influence on the actual savings and efficiency of the electrified drivetrain. ZF can draw on its longtime experience with vehicle drivetrain control on tractors as well as experience coming from passenger and commercial vehicles hybrid projects.