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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
3
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5
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.
1110
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
Suspension 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
13
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.
1414
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
Suspension Technology
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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