Shaping SMART LOGISTICS - ZF Friedrichshafen AG

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Shaping SMART LOGISTICS - ZF Friedrichshafen AG
vision – THE ZF MAGAZINE
                                                   3/2018

                        3/2018

                                                                                                                vision
                                                   Shaping
                                                   SMART LOGISTICS
                        vision – THE ZF MAGAZINE

ZF Friedrichshafen AG                              AUTONOMOUS VAN                 FORMUL A E EVERY WHERE
88038 Friedrichshafen
Germany                                            Mastering the last mile with   How ZF is bringing electric
zf.com                                             innovative ZF technology       drives to all vehicles
Shaping SMART LOGISTICS - ZF Friedrichshafen AG
Contents                                                  32
                                                           CL E A N A IR A ND
                                                           EF F ICIENC Y GO X X L
                                                           Safe and pollution-free: that’s the promise heralding
08                                                         electrified autonomous commercial vehicles. ZF’s
 T IME FOR A R EB OOT                                      electromechanical steering system prototype makes
                                                           this a reality.
Freight transport is rapidly increasing worldwide.
More and more freight and delivery vehicles
are clogging up city streets. The logistics system
                                                          34
as we know it is threatening to collapse. Improved
interconnectedness could be the answer to                  NE W HEIGH TS
significantly improving efficiency.
                                                           Major Chinese corporations are working intensely
                                                           on the technologies of tomorrow, one of which
                                                           is artificial intelligence (AI). And ZF is right there
16
                                                           alongside them.

                                                                                                                                                             ZF HIGHLIGHT
 S AT I SFAC T ION INCLUDED –
 R IGH T TO YOUR D OOR                                    37
Logistics service providers deliver billions of
                                                           SPE A K ER S ’ COR NER

                                                                                                                    Innovatively
shipments annually. An autonomous concept vehicle
developed by ZF is revolutionizing the “last mile”         Norway has accumulated years of experience
to the benefit of both drivers and customers.              with electric vehicles on a grand scale. How does
                                                           e-mobility work there, and what aspects could

                                                                                                                    Lightweight
                                                           we adopt in other countries?
20
 AU TONOMOUS CO S T- CU T T ING                           38
ZF is using smart concepts to demonstrate how
                                                           MIR ACULOUS
logistics can be made safer and more cost-effective
both on the road and at the depot. The key to it all is    T R A NSFOR M AT ION
autonomous driving features.
                                                           Remanufacturing is a sustainable alternative to                                                   A K N E E A I R B A G I N A FA B R I C H O U S I N G? I N D U S -
                                                           new production. Discover how ZF is giving products                                                TRY EXPERTS SAID IT COULDN’ T BE DONE. BUT
                                                           a new lease on life as we take you on a tour of our                                               T H AT ’ S P R E C I S E LY W H AT Z F W I L L B E B R I N G I N G
24                                                         Frýdlant location in the Czech Republic.                                                          T O V O L U M E P R O D U C T I O N I N 2 019 .
 A COMPA N Y F UL L OF ENER G Y
ZF supplies an incredibly diverse range of electric
drive systems that power everything from bicycles                                                                                                                The heavier a vehicle is, the higher its emissions under
to heavy goods trains. This portfolio makes the                                                                                                              combustion and the lower its range under electric power.
technology company unique in the mobility sector          C AT EGOR IE S                                                                                     All the more reason to minimize the weight of individual
                                                                                                                                                             components. ZF’s new knee airbag is much more than just
                                                                                                                                                             a standard improvement in this respect. At just 700 grams,
                                                                                                                    The ZF knee airbag is the lightest and
28                                                        3             Editorial
                                                                                                                      smallest the industry has ever seen.
                                                                                                                                                             the module weighs some 30% less than comparable prod-
                                                                                                                                                             ucts. So how did we do it? A world first: the airbag hous-
 T HE DY N A MIC SEDA N                                   4–5           ZF Moment
                                                                                                                                                             ing is made of fabric instead of metal. The concept can
ZF’s new active damping system, sMOTION, takes            6–7           Facts and Figures                                                                    be adapted to the needs of any market or vehicle model.
driving comfort, dynamics and safety to a whole                                                                                                              Yet another advantage is that it requires around 20% less
                                                          14 – 15       Did You Know?
new level. That’s a huge plus when it comes to                                                                                                               installation space. So it’s not just the lightest in the indus-
highly automated driving.                                 44 – 46       In a Nutshell                                                                        try, but also the most compact. In early 2019, a major
                                                                                                                                                             European manufacturer will be starting volume production
                                                          46            Masthead
                                                                                                                                                             of our fabric airbag module.
                                                          47            ZF Highlight
Shaping SMART LOGISTICS - ZF Friedrichshafen AG
Smart
                                         Am I the only one who gets riled by double-parked
                                         delivery vehicles blocking the street and causing jams?
                                         I see it all the time. And the couriers are just as stressed

logistics is
                                         out. Time is short, and parking space is a rare commod-
                                         ity, so it’s no wonder they resign themselves to annoying
                                         other road users and just pulling up wherever they can.        ·
                                                                                                        ·

the way
                                         And last but not least, logistics companies themselves         ·

                                         are battling to solve this issue of the last mile. Looking     3
                                                                                                        ·
                                         for parking spaces and constantly getting in and out of        ·
                                                                                                        ·

forward
                                         the van slows down deliveries and consequently drives
                                         up costs.
                                         Fortunately, I can promise you that next-generation

for mobility
                                         mobility will make this scenario a thing of the past. So
                                         what is ZF doing about it? We’re applying our unique
                                         system expertise to deliver high-precision smart logis-
                                         tics solutions so that, for example, a delivery vehicle
                                         can look for its own parking space, or can follow cou-
                                         riers as if on a virtual leash while they make deliveries
                                         on foot.
                                         It’s no coincidence that we’re making great strides in
                                         autonomous driving features specifically for commer-
                                         cial vehicles. My view is that we’ll see early adoption
                                         of these in manageable areas like depots or specially
                                         designated downtown zones.
ZF IS WORKING RESOLUTELY TO ENSURE       We’ll be exhibiting many more exciting innovations
THAT ITS SYSTEM SOLUTIONS ARE FULLY      at this year’s International Motor Show. But these are
NET WORKED, AND TO PL AY A MA JOR ROLE   not just a vague promise: we’re already delivering
IN SHAPING THE FUTURE OF MOBILIT Y       next-generation mobility products. Read on for a taste
THROUGH DIGITALIZ ATION.                 of what is, and what’s to come!

                                                                       Wolf-Henning Scheider
                                                                       Chief executive officer
                                                                       ZF Friedrichshafen AG
Shaping SMART LOGISTICS - ZF Friedrichshafen AG
·
                                                                                                                                     ·
                                                                                                                                     ·
                                                                                                                                     5
                                                                                                                                     ·
                                                                                                                                     ·
                                                                                                                                     ·

Z F MOMEN T

Heavyweights   Towboats and barges are a common sight on US inland waterways. According the American Waterways Operators
               industry association, 60 percent of US grain destined for export is transported this way. A typical "tow," which
               consists of 15 interconnected cargo barges, transports the same volume of cargo as 1,050 large semi-trailer

on the water
               trucks. Our photo shows the 23-meter long, 11-meter wide American Power on the Ohio River. Two 360°-steerable
               azimuth thrusters (series 5000) from ZF propel this American Commercial Barge Line tugboat, providing maximum
               maneuverability. Not only do thrusters boost safety on the winding river, their efficient design also ensures lower
               emissions, providing the same thrust as conventional shaftlines, but with a smaller engine size.
Shaping SMART LOGISTICS - ZF Friedrichshafen AG
C H I N E S E C O N TA I N E R C H A M P I O N

                                                                                                                                                                                With an annual throughput of 37 million standard
                                                                                                                                                                                20-foot containers, Shanghai is the biggest
                                                                                                                                                                                container port in the world. Incidentally, six of
                                                                                                                                                                                the top ten largest container ports are in China.

                                                                                      Logistics                                                                                                                          2000               20

                      Right place,
                       right time                                                                                      PA R CEL B OOM
···

                                                                                                                       In 2016, Germany’s courier, express and parcel (CEP)
SMART LOGISTICS

                                                                                                                       services delivered around 3.16 billion shipments;
                                                                                                                       that’s over 10 million per delivery day. Volumes have                                                                ·
                                                                                                                                                                                                                                            ·
                                                                                                                                                                                                                                            ·
                              B E H I N D E V E R Y T I M E LY D E L I V E R Y O F G O O D S L I E S A                 doubled since 2000. The German Association for Mail                                                                  7
                  S O P H I S T I C AT E D S U P P LY C H A I N . R E A D O N F O R S O M E I N T E R E S T I N G      and Express Logistics (BIEK) estimates that annual                                                                   ·
                                                                                                                                                                                                                                            ·
                                                                                                                                                                                                                                            ·
                                      A N D C U R I O U S FA C T S A B O U T L O G I S T I C S .                       volumes will reach approximately 4.15 billion by 2021.
···

                                                                                                                                                                                ASTRONOMICAL
                                                                                                                                                                                PRICES                     04-05-18
                                                                                                                                                                                                           20°C
                                                                   THE SMART PORT                                                                                                                          302.5g
                                                                                                                                                                                Supplying another celestial object is a very parti­c ular
                                                                                                                                                                                kind of logistical challenge. First, it requires enough
                                                                                                                                                                                fuel on board for the whole journey; and second,
                                                                   In one of the terminals at the Port of Melbourne,
                                                                                                                                                                                there’s no “roadside assistance” in space if something
                                                                   automated cranes unload freight and move
                                                                                                                             2000            2016            2022               breaks down. As you’d expect, the prices are equally
                                                                   containers without human intervention. Trucks
                                                                                                                                                                                astronomical: sending a kilo of freight to the moon
                                                                   are automatically identified and routed by the
                                                                                                                                                                                currently costs in the region of $41,000.
                                                                   logistics system. The system then issues loading
                                                                   and unloading orders to the cranes and container
                                                                   trucks. Cargo handling at the terminal is now six
                                                                   times faster than under the old system.
                                                                                                                       L O S S E S W I T H A H E AV Y P R I C E

                                                                                                                       Around a third of all foodstuffs produced in the
                                                                                                                       world never actually reach consumers; they perish                                     04-05-18
                                                                                                                       during storage, transport or processing. Modern                                       20°C
                                                                                                                       technologies like condition monitoring are critical                                   302.5g
                                                                                                                       in reducing these losses, for example by promptly
                                                                                                                       flagging up breaks in the cold chain.
                                                                                                                                     2000           2016          2022

                                                                                                                         2000                          2016                      2022
Shaping SMART LOGISTICS - ZF Friedrichshafen AG
Time for a reboot
···
SMART LOGISTICS

                                                                                                                          ·
                                                                                                                          ·
                                                                                                                          ·
                                                                                                                          9
                                                                                                                          ·
                                                                                                                          ·
                                                                                                                          ·
···

                    F R E I G H T T R A N S P O R T B Y L A N D, S E A A N D A I R I S R A P I D LY I N C R E A S I N G
                       WORLDWIDE. MORE A ND MORE GOODS V EHICLES A RE CLOGGING
                           UP CIT Y STREE TS. THE LOGISTICS SYSTEM AS WE K NOW IT IS
                       T H R E AT E N I N G T O C O L L A P S E . B U T E X P E R T S A R E O P T I M I S T I C T H AT
                          B E T T E R I N T E G R AT I O N C O U L D B E T H E A N S W E R T O I M P R O V I N G
                                                   E F F I C I E N C Y S I G N I F I C A N T LY.

                                                         Text: Martin Westerhoff
Shaping SMART LOGISTICS - ZF Friedrichshafen AG
T
                            he roar of a Boeing 747                                                                                                                                                              chain (the “first mile”), the transit
                            cargo freighter briefly                                                                                                                                                              chain and the delivery chain (the
                            shattered the surreal                                                                                                                                                                “last mile”). The Department of
                            silence that had reigned                                                                                                                                                             Industrial Engineering and Inno-
                  over the ports of Los Angeles and                                                                                                                                                              vation Sciences at Eindhoven Uni-
                  Long Beach for days. The pilots                                                                                                                                                                versity of Technology has defined
                  were headed for Japan. Below                                                                                                                                                                   the intricacy of this challenge in
                  them, tens of thousands of sea                                                                                                                                                                 no uncertain terms. According
                  containers were stacking up on                                                                                                                                                                 to the Dutch researchers, smart
                  the ground. And the plane’s                                                                                                                                                                    logistics implies synchronizing four
                  cargo? Ton upon ton of frozen                                                                                                                                                                  domains: a logistics system only
                  French fries.                                                                                                                                                                                  works efficiently if scheduling, ICT,
                                                                                                                                                                                                                 personnel and legislation are well
                      Seriously? Flying fries to Japan?                                                                                                                                                          aligned.
                  It may sound downright unbeliev­able,
                  but in December 2014 it became                                                                                                                                                                      INTO THE UNK NOWN
                  a very costly reality for one US fast
                  food chain. At the time, the two                                                                                                                                                                   This system can very easily get
                  West Coast ports were notoriously                                                                                                                                                              out of step, requiring rapid inter-
                  overburdened. The dockworkers                                                                                                                                                                  vention. A case in point is the sce-
                  went on strike, leaving restaurant                                                                                                                                                             nario playing out since late May
                  managers to deal with the chaos                                                                                                                                                                2018 in Hamburg, the first German
                  caused by a serious shortage of                                                                                                                                                                city to ban non-Euro 6 diesel vehi-
···

                  the one thing a hamburger is simply                               Logistics centers and warehouses have a long way to go in                                                                    cles from two of its streets. “Bans
                  not complete without. It was not just                             terms of efficiency. Intelligent solutions are the answer.   STREETS IN                                                      inevitably drive change. This
SMART LOGISTICS

                  the wrath of Japanese customers –                                                                                                                                                              shows just what a hot topic the
                  who were having their fries rationed –                                                                                         DIRE STRAITS                                                    last mile is,” warned Professor Uwe
                                                                                                                                                                                                                                                         ·
                                                                                                                                                                                                                                                         ·
                                                                                                                                                                                                                                                         ·

                  that was at stake. Sales had already                                                                                                                                                           Clausen of the Fraunhofer Institute     11
                                                                                                                                                                                                                                                          ·
                  dropped by 21 percent, and the strike                                                                                          According to an OECD survey, international road freight         for Material Flow and Logistics          ·
                                                                                                                                                                                                                                                          ·
                  threatened a further slump as well as                                                                                          transportation grew by 96.12 percent between 2001 and           (IML), speaking at the first courier,
                  considerable reputational damage for                                                                                           2015. Across the 47 countries in the sample, haulage            express and parcel services indus-
···

                  the fast-food chain with its 3.000-plus                                                                                        capacity rose from roughly 7 trillion ton-kilometers (tkm)      try conference (CEP), which was
                  restaurants in Japan. Ultimately, over                                                                                         to over 14 trillion. A ton-kilometer is a unit of measurement   staged last year by German pub-
                  1,000 tons of “flying fries” were sent                                                                                         obtained by multiplying the volume transported by the           lisher EuroTransportMedia (ETM)
                  to the Land of the Rising Sun as                                                                                               distance traveled to deliver it.                                with ZF’s support.
                  a result of the strike.

                          IMPROVING
                                                            system and traffic as a whole can
                                                            only work efficiently if it’s suffi­
                                                                                                                                                 2001                                                               U N D E R T H E S P O T L I G H T:
                                                                                                                                                                                                                          THE L AST MILE
                     LOGISTICAL EFFICIENCY                  ciently well connected,” says
                       THROUGH BET TER                      Majid Sarvi, a professor of trans-                                                                                                                       A host of current logistics
                         CONNEC TIVIT Y                     port engineering at Melbourne                                                                                                                        developments and innovations
                                                            University.                                                                                                                                          are focused on the last mile along
                                                                                                                                                 7.16 5 T R I L L I O N T K M
                      This anecdote shows what                                                                                                                                                                   with upstream transfer from the
                  a tightly woven web global trade              Boosting communication                                                                                                                           transit chain – so not just on ship-
                  really is, and the far-reaching           between the means of transpor-                                                                                                                       ping, but also on depots and ware-
                  consequences of an interruption,
                  let alone a break, in the logistics
                                                            tation, the goods and the infra-
                                                            structure is among the core tasks
                                                                                                                                                 2015                                                            houses. The reasons are twofold.
                                                                                                                                                                                                                 First, the rapidly accelerating pace
                  chain. According to forecasts by          of a new discipline dubbed “smart                                                                                                                    of the mail-order business; and
                  the EU Commission, road, rail and         logistics.” Smart logistics aims to                                                                                                                  second, the ongoing trend toward
                  maritime freight traffic is set to        help meet the challenges posed                                                                                                                       global urbanization. The net result
                  increase by 25 percent between            by a growing number of unknowns                                                                                                                      is spiraling demand for deliveries to
                  2010 and 2030. In light of this,          and an increasingly complex trans-                                                                                                                   city-dwellers. According to United
                  logistics specialists are calling         portation chain. The transportation                                                                                                                  Nations (UN) estimates, 55 per-
                  for urgent action. “The logistics         chain is made up of the collection                                                   14.050 TRILLION TKM                                             cent of the world’s 7.62 billion
Shaping SMART LOGISTICS - ZF Friedrichshafen AG
“A networked
                  inhabitants are urbanites today;
                  by 2050, that proportion will have
                  risen to 68 percent.

                      According to a UN report pub-
                  lished in May, the pace of urbaniza-
                                                                         traffic system is
                                                                       essential for more
                  tion is particularly fast in develop-
                  ing and emerging countries. The
                  latest figures from China’s National

                                                                       efficient logistics.”
                  Office for Statistics reveal that
                  58.52 percent of the nation lives
                  in urban areas. Professor George
                  Q. Huang, chair of industrial and
                                                                                                            MAJID SARVI
                  manufacturing systems engineering
                                                                               Professor of transport engineering, Melbourne University
                  at Hong Kong University, outlines
                  the situation in the vast economic
                  area that takes in China, Hong
                  Kong and Taiwan: “E-commerce in
                  Greater China has exploded in the                                                                                             An everyday scenario in downtown areas across the globe: delivery vehicles obstructing traffic.
                  last few years, which means that
                  delivery logistics are increasingly
                  becoming a bottleneck.”
···
SMART LOGISTICS

                                                                                                       Indeed, more and more ware-                                        Logistics Parks.” These solutions                TESTING TOMORROW ’S                  ·
                                                                                                                                                                                                                                                                ·
                                                                                                   houses on various scales are spring-                                   are intended to synchronize the                     T R A F F I C T O D AY            ·

                                                                                                   ing up across mainland China to                                        complex processes involved                                                            13
                                                                                                                                                                                                                                                                 ·
                                                                                                   accommodate online orders. “How-                                       and to coordinate them more                     Melbourne University is running        ·
                                                                                                                                                                                                                                                                 ·
                                                                                                   ever, they’re still using old-school                                   effectively. Huang also predicts            trials in an inner city area of six
                                        Long-haul transport too will benefit                       logistics systems that don’t stand up                                  a paradigm shift in automation              square kilometers to examine how
···

                                        from networked logistics concepts.                         to present and future requirements,”                                   with autonomous robotics, but its           this kind of smart transportation
                                                                                                   says Huang. For example, the time                                      progress is currently hampered              system might work. With the help
                                                                                                   from receiving an incoming order to                                    by the excessive amortization               of over 40 partners including indus-
                                                                                                   handing over the package to a logis-                                   periods involved.                           trialists, policymakers and research-
                                                                                                   tics company is too long. Space uti-                                                                               ers, university engineers are devel-
                                                                                                   lization in these logistics parks also                                     Professor Majid Sarvi is equally        oping and testing communication
                                                                                                   leaves much to be desired.                                             convinced that the logistics sector         systems for vehicle-to-vehicle (V2V),
                                                                                                                                                                          cannot solve the last-mile issue            Vehicle-to-­v ulnerable-road-users
                                                                                                   P R O C E S S S Y N C H R O N I Z AT I O N                             alone. Rather, it’s about looking           (V2P) and vehicle-to-infra­s tructure
                                                                                                             AND IMPROVED                                                 at traffic as a whole. “Transporta-         (V2I) use. Sensors record the flow
                                                                                                             C O O R D I N AT I O N                                       tion is a multimodal system made            of motor vehicles, cyclists, pedes-
                                                                                                                                                                          up of all means of transport, plus          trians and public transportation in
                                                                                                      “But one of the most critical                                       the infrastructure,” says Sarvi.            real time. This connected system
                                                                                                   factors is a lack of synchronization                                   Efficiency will only improve if we          is called the Australian Integrated
                                                                                                   between the three stages – goods                                       can network the entire system so            Multimodal EcoSystem (AIMES).
                                                                                                   manufacturer to logistics park,                                        as to coordinate and optimize it.
                                                                                                   order compilation at the park,                                         “The same applies to autonomous                 “A productive transport system is
                                                                                                   and customer deliver y,” Huang                                         cars: they only deliver advantages          essential not just for urban quality of
                                                                                                   laments. The institute he heads                                        if they’re linked with a central data       life, but also for an economy to com-
                                                                                                   up is currently working on cloud-                                      platform that monitors the whole            pete globally,” Sarvi reiterates. He
                                                                                                   based solutions for a project                                          transport business – including              sums it up perfectly, and that’s why
                                                                                                   dubbed “iPark: Core Technolo-                                          traffic lights and pedestrians,”            smart logistics solutions are such a
                                                                                                   gies of Intelligent Ecommerce                                          he explains.                                high priority for tomorrow’s society.
Shaping SMART LOGISTICS - ZF Friedrichshafen AG
The steam engine, invented by James Watt in
                                                                                                                                        1769, and the development of the railroads took the
                                                                                                                                        transport of goods to a whole new level. The turn
                                                                                                                                        of the nineteenth century heralded the advent of
                                                                                                                   1830                 the steam locomotive, and 1830 saw the inaugura-
                                                                                                                                        tion of the first rail route for freight – the Liverpool
                                                                                                                                        and Manchester Railway. From then on, the use
                                                                                                                                        of freight cars has risen steadily, and benchmarks
                                                                                                                                        such as the 1,435 millimeter standard gage became
                                                                                                                                        the norm.

                                                                                                                                           In 1907, with $100 of seed capital and two bicy-
                                                                                                                                        cles, Seattle-based US entrepreneur James E. Casey
                                                                                                                                        founded the world’s first parcel delivery service – the
                                                                                                                                        American Messenger Company, which would later

                  did you know?
                                                                                                                                        become the United Parcel Service (UPS). Today, UPS
                                                                                                                            1 90 7      has a fleet of 237 aircraft and 108,210 delivery cars,
                                                                                                                                        vans, haulers and motorcycles dedicated to deliver-
                                                                                                                                        ing packages. Over 8,100 of its vehicles are powered

                  Milestones
                                                                                                                                        by alternative fuels and advanced technologies.

                                                                                                                                            In the early 1950s, Toyota engineer Taiichi
                                                                                                                                        Ohno was tasked with boosting the car company’s
···

                                                                                                                                        productivity. While visiting a supermarket in the

                  in modern
                                                                                                                                        US, he had a eureka moment. Today we call
SMART LOGISTICS

                                                                                                                                        it the “ just-in-time” concept. Ohno realized that           ·
                                                                                                                                                                                                     ·
                                                                                                                                        people only purchased what they needed then                  ·

                                                                                                                                1 953   and there, and that in principle a supermarket               15
                                                                                                                                                                                                      ·
                                                                                                                                        was simply a well-run warehouse. He saw that                  ·
                                                                                                                                                                                                      ·

                  logistics
                                                                                                                                        if incoming goods matched outgoing goods as
                                                                                                                                        accurately as possible, no long-term storage
···

                                                                                                                                        space was required.

                                                                                                                                            On April 26, 1956, Malcom McLean launched the
                                                                                                                                        world’s first container ship – the Ideal X. Prior to this,
                                                                                                                                        he had grown the McLean Trucking Company into the
                                                                                                                                        second-largest freight forwarder in the US in a just
                  G L O B A L T R A D E A S W E K N O W I T T O D AY W O U L D B E U N T H I N K A B L E                                few short years. He then sold 75 percent of the com-
                  W I T H O U T C E R TA I N G R O U N D B R E A K I N G L O G I S T I C S I N V E N T I O N S .            1 95 6      pany and invested in ships. After a few modifications,
                  HERE ARE SOME OF THOSE SEMINAL MOMENTS.                                                                               McLean equipped the Ideal X with 58 steel boxes that
                                                                                                                                        were built in-house and tailor-made to fit the chassis
                                                                                                                                        of his trucks. Containerization was born, and has
                                                                                                                                        since become the world’s leading method of freight
                                                                                                                                        transportation. Then came an invention that revolu-
                                                                                                                                        tionized logistics: the barcode. At the time, the indus-
                                                                                                                                        try paid it scant attention.

                                                                                                                                            But many subsequent innovations, such as auto-
                                                                                                                                        matic tracking or modern warehousing, would have
                                                                                                                                        been inconceivable without it. Americans Norman
                                                                                                                   1 9 74               Joseph Woodland, George Laurer and Bernard Silver
                                                                                                                                        are credited as its inventors. Incidentally, the very
                                                                                                                                        first barcoded product, scanned on June 26, 1974
                                                                                                                                        by a cashier in Ohio, was a 10-pack of gum.
Shaping SMART LOGISTICS - ZF Friedrichshafen AG
···
SMART LOGISTICS

                                                                                                                                                                                                                                                   ·
                                                                                                                                                                                                                                                   ·
                                                                                                                                                                                                                                                   ·
                                                                                                                                                                                                                                                   17
                                                                                                                                                                                                                                                    ·
                                                                                                                                                                                                                                                    ·
                                                                                                                                                                                                                                                    ·
···

                                                                                                                                                              If necessary, the van drives on autonomously while the courier makes the delivery.

                  Satisfaction
                  included – right                                                                                                                            O
                                                                                                                                                                         nline retail is so practical.    you may find your package sitting
                                                                                                                                                                         One click and your goods         on your doorstep, where anyone
                                                                                                                                                                         are on their way to your         could simply walk away with it.
                                                                                                                                                                         door. At least that’s the        However, it’s not just those await-
                                                                                                                                                              theory. But in practice, the hassle         ing delivery who are feeling hassled.

                  to your door
                                                                                                                                                              often starts as soon as you get your        In downtown areas with a lack of
                                                                                                                                                              order confirmation: the delivery            parking space, delivery trucks block-
                                                                                                                                                              deadline is etched in stone. The            ing the road are a common sight.
                                                                                                                                                              delivery window you’re given forces         According to a study by auditing
                                                                                                                                                              you to take the day off or work from        and consulting firm PwC, goods
                                                                                                                                                              home. And far too often you still           traffic is responsible for 80 percent
                  LOGISTICS SERVICE PROVIDERS DELIVER BILLIONS OF SHIPMENTS A YE AR. A NEW                                                                    find a card in your mailbox telling         of rush-hour jams in the city. The
                  Z F C O N C E P T V E H I C L E H E R A L D S A B E T T E R WAY T O M E E T T H E C H A L L E N G E S O F T H E                             you the package is waiting for              study’s authors also found that one
                  F I N A L D E L I V E R Y S TA G E , K N O W N A S T H E “ L A S T M I L E .”                                                               collection at a package shop or has         in three Germans is unhappy with
                                                                                                                                    Text: Kathrin Wildemann   been left with a neighbor. Equally,         their package deliveries.
You want to see the ZF Innovation Van
                                                                                                in action? Just scan the QR code
                                                                                                                                                                                                                          A VISION OF
                                                                                                                                                                                                                          THE FUTURE
                                                                                                            and enjoy the video.

                                                                                                                                                                                                                          FOR COURIERS
                                                                                                                                                        3

                                                                Meanwhile, couriers are under                TA K I N G T H E S T R A I N
                                                             extreme time pressure, often hav-                   OFF DRIVERS
                                                             ing to deal with 200 consignments
                                                             a day. On average, they have barely          What’s more, customers can
                                                             three minutes to get to the next         use an app to track where their
                                                             customer’s address, park, find the       package is at any time as well as
                                                             right front door and hand over the       to enter or change their preferred
                                                             package. And it’s even more irritat-     delivery time and location at short
                                                             ing if the recipient is out and they     notice. The system then calculates
                                                             have to try again later. ZF has the      a new route in real time. Obviously,
                                                             technology to make life easier for       it takes account of the current traf-
                                                             both parties: a driverless van with      fic situation and predicts the deliv-
                                                             an intelligent delivery system that      ery window reliably. All of this data
                                                             networks the package, the courier        converges in the ZF cloud, which
                                                                                                                                                    2
···

                                                             and the recipient.                       in turn sends it to couriers via data
                                                                                                      glasses, allowing them to prepare
SMART LOGISTICS

                                                                 The ZF Innovation Van finds the      en route for the next delivery while                                                                                                                       1
                                                                                                                                                                                                                                                                                  ·
                                                                                                                                                                                                                                                                                  ·
                                                             most efficient delivery sequence         the smart van does the driving.                                                                                                                                             ·

                                                             at any given time, using a cloud-                                                                                                                                                                                    19
                                                                                                                                                                                                                                                                                   ·
                                                             based support system that stores             The vehicle’s camera, radar and                                                                                                                                          ·
                                                                                                                                                                                                                                                                                   ·
                                                             relevant data for each consign-          LIDAR systems map its surroundings
                                                             ment, such as delivery location and      in the form of a data cluster, and        1                                         2                                              3
···

                                                             preferred timeslot. “The package         the AI-capable ZF ProAI central
                                                                                                                                               The van stops in a no-parking zone. The   While the courier is on the way to the         The data glasses relay the location to
                                                             practically finds its own way there,”    computer converts this to instructions
                                                                                                                                               courier hops out with the consignment.    customer’s door, the van slips back into       the courier, who gets back in where the
                                                             Georg Mihatsch, the project man-         for the chassis, steering system and
                                                                                                                                                                                         the flow of traffic and looks for a suitable   van is parked.
                                                             ager who oversaw development of          drive actuators. As a result, the van
                                                                                                                                                                                         place to stop.
                                                             the ZF Innovation Van, explains.         steers itself safely and independently

                  While the courier delivers the package, the van drives on autonomously
                  and finds itself a parking spot.

                                                                                                                                                                                         through even the most labyrinthine             turn receive their goods right on
                                                                                                                                                                                         city traffic. But what about the               time. It goes without saying that
                                                                                                                                                                                         blocked streets? We thought of                 as a technology company work-
                                                                                                                                                                                         that too. So if there’s no parking             ing to shape the future of mobility,
                                                                                                                                                                                         space at the delivery address, the             ZF always factors in environmen-
                                                                                                                                                                                         Innovation Van drops off the driver            tal impact. Courtesy of a central
                                                                                                                                                                                         and looks for a suitable place to              electric axle drive, the ZF Innova-
                                                                                                                                                                                         stop. This means that couriers                 tion Van is not only pollution-free,
                                                                                                                                                                                         can focus on their job – delivering            but also quiet and therefore
                                                                                                                                                                                         packages to customers, who in                  resident-friendly.
T
                                                                                                                                        here was a time when truck
                                                                                                                                        drivers were regarded as
                                                                                                                                        the last of the adventurers.

                  Autonomous
                                                                                                                                        But the freedom of the open
                                                                                                                             highway has long since given way to
                                                                                                                             a complex agenda. As they go about
                                                                                                                             their daily routine, today’s truckers
                                                                                                                             have to reconcile the requirements of

                  cost-cutting
                                                                                                                             their forwarding companies and its
                                                                                                                             customers, of legislators and of other
                                                                                                                             road users. It’s all about transporting
                                                                                                                             wares quickly, safely and as economi-
                                                                                                                             cally as possible.

                                                                                                                              T H E M O D E R N - D AY C O N V OY

                                                                                                                                 Proper organization is a big help
                                                                                                                             here. The result is platooning, where
···

                                                                                                                             several trucks travel one behind the
SMART LOGISTICS

                                                                                                                             other with a minimal clearance of up
                                                                                                                             to eight meters in between trucks.        ·
                                                                                                                                                                       ·
                                                                                                                                                                       ·
                                                                                                                             To prevent this from affecting road       21
                                                                                                                             safety, the vehicles are networked.        ·
                                                                                                                                                                        ·
                                                                                                                                                                        ·
                                                                                                                             All but the first are automated. The
                                                                                                                             entire platoon brakes as soon as the
                                                                                                                             driver of the lead truck steps on the
···

                                                                                                                             brake. Each truck drives in the slip-
                                                                                                                             stream of the one in front, saving
                                                                                                                             up to 15 percent fuel compared to
                                                                                                                             each one traveling on its own. The
                                                                                                                             drivers of the trucks at the rear have
                                                                                                                             no need to keep their eyes glued to
                                                                                                                             the road. They just have to be able
                                                                                                                             to take the wheel when the systems
                                                                                                                             are switched off.

                  Z F I S U S I N G N E W C O N C E P T S T O D E M O N S T R AT E H O W T O M A K E L O G I S T I C S           Martin Mayer, global key
                  S A F E R A N D M O R E C O S T- E F F E C T I V E , B O T H O N T H E R O A D A N D AT T H E D E P O T.   account manager for commercial
                  T H E K E Y T O I T A L L I S A U T O N O M O U S D R I V I N G F E AT U R E S .                           vehicle ADAS at ZF, works with
                                                                                                                             development to advance the tech-
                                                                                                                             nology that makes platooning pos-
                  Text: Andreas Neemann
                                                                                                                             sible. “The system is based on our
                                                                                                                             sensors and control electronics,
                                                                                                                             which enable the truck's automated
                                                                                                                             driving capabilities,” he explains.
the logistics chain.”
                  innovation vehicles optimize

                                                               Head of ADAS Project Center
                       “Our smart, networked

                                                   MARK MOHR
                                                                                                                     The systems-integration capable
                                                                                                                     ReAX truck steering system and
                                                                                                                     the TraXon automatic transmission
                                                                                                                     system receive steering and accel-
                                                                                                                     eration commands direct from the
                                                                                                                     control electronics.

                                                                                                                         The ZF Pro AI is the command
                                                                                                                                                                                                 The ZF Innovation Truck: drivers could park this hybrid truck on arrival at the
                                                                                                                     box in charge of it all. This unit is
                                                                                                                                                                                                         depot and take a break while automation takes care of the shunting.
                                                                                                                     so powerful that it evaluates the
                                                                                                                     enormous amounts of information
                                                                                                                     coming from the sensors in a
                                                                                                                     fraction of a second and converts
                                                                                                                     it to commands using intelligent                                            ZF’s approach is to make depot          management system has the
                                                                                                                     algorithms. ZF is currently involved                                    processes easier, safer and more            potential to make today’s standard
                                                                                                                     in a variety of platooning projects                                     reliable through autonomous                 freight documentation obsolete.
                                                                                                                     with truck manufacturers.                                               driving, which in turn would also
                                                                                                                                                             Take a look behind the gates    make them more cost-effective.                  The ZF Innovation Truck can
···

                                                                                                                          NEW FREEDOMS –                     of the depot of the future –    ZF is demonstrating this using a            carry out lots of tasks without a
                                                                                                                       THE AUTONOMOUS DEPOT                  simply scan the QR code and     coherent concept centering on ZF’s          driver. It finds its own way to its
SMART LOGISTICS

                                                                                                                                                             watch the video.                Innovation Truck, with our Terminal         target position at the depot, puts        ·
                                                                                                                                                                                                                                                                                   ·
                                                                                                                          Once the truck drivers reach                                       Yard Tractor as a shunter. “Our             down its loaded exchangeable              ·

                                                                                                                     their destination, there’s more work                                    concept incorporates the logistics          container and picks up another con-       23
                                                                                                                                                                                                                                                                                    ·
                                                                                                                     to do: they have to hand over freight                                   infrastructure of the forwarding            tainer. Even experienced truckers          ·
                                                                                                                                                                                                                                                                                    ·
                                                                                                                     documents at the incoming goods                                         agent. So we have a large part of           need extensive practice and abso-
                                                                                                                     department, park and wait. Break                                        the logistics chain in the frame,”          lute concentration to inch the
···

                                                                                                                     time? Forget it. At any moment they                                     says Mark Mohr, head of ZF’s                vehicle backwards into position
                                                                                                                     may have to get back in the truck,                                      commercial vehicle ADAS project             under the container. More often
                                                                                                                     maneuver it to the loading ramp and                                     center.                                     than not, property gets damaged.
                                                                                                                     decouple the trailer for unloading.                                                                                 But the ZF Innovation Truck con-
                                                                                                                     It's an intricate maneuver that                                            Smart tags can be attached to            sistently carries out this maneuver
                                                                                                                     requires the utmost concentration.                                      the cargo containers while they             quickly, accurately and as safely
                                                                                                                     After a long haul, no breaks and                                        are on the truck. These provide             as possible. The shunting is done
                                                                                                                     yet more taxing maneuvers, drivers                                      digital information, for example            by another ZF innovation vehicle,
                                                                                                                     are often completely exhausted.                                         on inventory, and also whether              the Terminal Yard Tractor. It picks
                                                                                                                     Last year in Germany alone, there                                       the cargo has been damaged en               up the trailer and moves it reliably
                                                                                                                     were 16,500 notifiable commercial                                       route by issues such as heavy               from place to place. And it can
                                                                                                                     vehicle work accidents that did not                                     vibrations or a break in the cold           work all day, every day – even 24/7
                                                                                                                     occur on the road, with 28 of them      Networked into the              chain. Transmitting the smart               if necessary – without any sign of
                                                                                                                     ending with fatalities.                 slipstream: platooned trucks.   tag data directly to the materials          fatigue.

                                                                                             Stress, fatigue and
                                                                                             distraction don’t
                                                                                             factor into it: the
                                                                                             Terminal Yard Tractor
                                                                                             shunts autonomously,
                                                                                             safely and precisely.
A company                                                                                                                N
                                                                                                                                    o more panting and wheezing your way
                                                                                                                                    uphill, and no more hot and sticky morning
                                                                                                                                    commutes – pedelecs have arrived! In 2017,
                                                                                                                                    almost one in four new bicycles sold in
                                                                                                                         Germany had an auxiliary electric motor. And thanks

full of energy
                                                                                                                         to ZF, sales are set to go on rising. The Group recently
                                                                                                                         became one of three partners in the newly founded
                                                                                                                         Sachs Micro Mobility Solutions GmbH. The kickoff for
                                                                                                                         this joint venture is the production launch of drive and
                                                                                                                         brake systems for pedelecs and e-bikes.

                                                                                                                                          ELEC TRONICS FOR
                                                                                                                                        P R I VAT E T R A N S P O R T

                                                                                                                             Hybrid passenger cars combine a combustion
                                                                                                                         engine with an electric motor. The hybrid module used
                                                                                                                         in ZF‘s 8-speed 8P automatic transmission supports
                                                                                                                         a host of hybrid applications that make it the ideal
                                                                                                                         solution. The mild version delivers up to 20 kW of extra      The 8P hybrid drive combines combustion
                                                                                                                         electric power. That‘s not enough for purely electric                         power with electric driving.
                                                                                                                         driving, so we designed a plug-in hybrid version of the
                                                                                                                         8P that makes it feasible. Its electric module boasts a
                                                                                                                         peak output of 90 kW and maximum torque of 250 Nm.
                                                                                                                         This boost in speed makes zero-emission driving at
                                                                                                                         up to 120 km/h possible over a good 50 km range,
                                                                                                                         depending on the onboard battery. ZF‘s 7-speed dual                                                           ·
                                                                                                                                                                                                                                       ·
                                                                                                                         clutch transmission was designed with a focus on                                                              ·

                                                                                                                         combustion. But its 8-speed successor, co-developed                                                           25
                                                                                                                                                                                                                                        ·
                                                                                                                         with Porsche as a 100 kW hybrid drive right from the                                                           ·
                                                                                                                                                                                                                                        ·
                                                                                                                         outset, is the opposite – a sure sign that electrically­
                                                                                                                         assisted mobility is becoming the norm. A variant with-
                                                                                                                         out an electric drive module is based on it.

                                                                                                                            ZF is also an expert in axle-based passenger car
                                                                                                                         electrification. Our mSTARS (modular Semi-Trailing
                                                                                                                         Arm Rear Suspension) axle system is even suitable
                                                                                                                         as a replacement for conventional rear axles in
                                                                        ZF HOLDS A UNIQUE POSITION                       existing vehicle platforms and is also equipped for
                                                                        IN THE MOBILIT Y SEC TOR                         the ZF eVD (Electric Vehicle Drive) axle drive mod-
                                                                        I N T H AT W E S U P P LY A N                    ule. With a peak output of 150 kW, this module lays        An electric drive integrated into ZF’s versatile
                                                                        I N C R E D I B LY D I V E R S E R A N G E O F   the foundations for all-electric compact cars. Com-                            mSTARS rear axle system.
                                                                        E L E C T R I C D R I V E S Y S T E M S T H AT   bined with a front-axle ICE drive, our electric axle
                                                                        POWER E V ERY THING FROM                         drive transforms vehicles into axle-hybrids and 4x4s.
                                                                        B I C YC L E S T O T R U C K T R A I L E R S .   In our recently unveiled concept vehicle equipped

                                                                        Text: Achim Neuwirth

 ZF cares about sustainable power generation too, with currently 55,000 wind turbine gearboxes worldwide.
“The driveline
                                                                                                                                                                         electrification can no
                                                 with eAMT (electrified Automated Manual Transmis-                                                                       longer be contained.
                                                 sion) it also compensates for the momentary loss of
                                                 propulsion when the automated transmission shifts,                                                                      To this end, we
                                                 providing continuous thrust.
                                                                                                                                                                         develop and deliver
                                                                (ALMOST) UNLIMITED
                                                                    E-MOBILIT Y                                                                                          core components
                                                     Our electric axle drive is also used as the sole drive      TraXon, our automatic transmission for heavy trucks     as well as entire
                                                 for minibuses. For example, it provides the acceleration     and buses, is also suitable for commercial vehicle

Thousands of ZF AxTrax AVEs with electric
                                                 for the e.GO Mover people and cargo mover, which is          hybridization. It‘s powerful enough to move a 40-ton       systems for all
                                                 designed for automated driving. e.GO Moove GmbH              truck at the depot solely with electric drive. Equally,
portal axles are already in operation on the
highways.
                                                 starts volume production of the vehicle in 2019. e.GO        industrial trucks such as forklifts can be powered by ZF   vehicle types.”
                                                 Moove is a joint venture between ZF and e.GO Mobile          electric drives in the 4.5 to 10 kW performance range.
                                                 AG. For much larger low-floor buses, we supply the           Take our Innovation Forklift, for example: ZF engi-        JÖRG GROTENDORST
                                                 AxTrax AVE electric portal axle, formerly the ZF AVE         neers taught it to drive not just electrically, but also   Head of e-mobility
                                                 130. It features two 125 kW electric motors and a            autonomously.
                                                 torque of 485 Nm. In articulated buses, it‘s even pos-
                                                 sible to install two AxTRAX AVEs. The drive is already           In off-road machinery, ZF‘s eTRAC drives are the
                                                 operational in parts of the urban public transport           basis for all-electric tractor concepts as well as for
                                                 fleets in Stuttgart, Mannheim and Bonn.                      unusual hybrid solutions: our electric Front Axle Drive                             ·
                                                                                                                                                                                                  ·
                                                                                                              (eFAD) combines torsion-free 4x4 drive with low                                     ·

                                                     CeTrax is yet another system from ZF allowing            consumption, while the eTRAC-GPE 50 electric wheel                                  27
                                                                                                                                                                                                   ·
                                                 all-electric driving for heavy commercial vehicles. This     head on our Innovation Tractor features an electric                                  ·
                                                                                                                                                                                                   ·
                                                 electric central drive boasts an output of 300 kW and        motor on both the left and right wheels of one of the
                                                 a torque of 4,400 Nm. Its little brother, CeTrax lite,       trailer axles. The electric drive provides up to 80 kW
                                                 features a 150 kW, 380 Nm module for delivery vans           when the tractor is on loose or muddy ground or when
                                                 and other light commercial vehicles weighing up to           driving up or on steep inclines. This trailer traction
                                                 7.5 tons. CeTrax mid is a dual package with two 150 kW       management system can often alleviate the need to
                                                 modules for medium-duty commercial vehicles up to            buy a bigger tractor. A plough electrified by ZF offers
The ZF CeTrax – our electric central drive for   19 tons.                                                     similar advantages.
commercial vehicles.
The dynamic                                                                      L
                                                                                           ong plastic ridges are       chassis components. Greger is used     suspension. If a wheel rolls over
                                                                                           stuck to the asphalt like    to passengers – many of them buy-      an obstacle, it lifts, compressing
                                                                                           oversized Band-Aids. They    ers or other research engineers        a spring between the steering
                                                                                           are there for one reason     from international automotive man-     knuckle and the car body. Then the
                                                                                  and one reason only: to wreak as      ufacturers – reacting this way on      spring decompresses. The shock

sedan
                                                                                  much havoc as possible on any         the proving ground. “Our sMOTION       absorber’s job is to attenuate the
                                                                                  car that crosses them. Unper-         fully active chassis system intro-     resulting vibration as quickly as
                                                                                  turbed, the driver steers his blue    duces new degrees of freedom to        possible. Aside from direct impact,
                                                                                  compact MPV onto this special         counteract vehicle body movement,”     vehicles have to contend with
                                                                                  shake and vibration track. One of     he says. “We can give each wheel       motive forces, braking forces and
                                                                                  the passengers in the back clutches   its own active countermovement         centrifugal forces. These forces
                                                                                  the handle above the window as        to prevent driving situations from     associated with driving dynamics
                                                                                  the minivan crosses the bumps         exciting the car body.” But along      can prompt the car body to move in
                                                                                  at full speed. But from inside the    with greater comfort, sMOTION sig-     the direction of three spatial axes
                                                                                  car, they're barely noticeable.       nificantly improves dynamics and       (see diagram below). The chal-
Z F ’ S N E W A C T I V E D A M P I N G S Y S T E M , S M O T I O N , TA K E S   “Impressive!” he gasps, releasing      safety compared to current systems.    lenge lies in the fact that different
D R I V I N G C O M F O R T, DY N A M I C S A N D S A F E T Y T O A W H O L E     his grip.                             Used in conjunction with cameras,      driving situations each demand a
N E W L E V E L . T H AT ’ S A H U G E P L U S W H E N I T C O M E S T O                                                the chassis system can identify        specific damping force. Minimizing
H I G H LY A U T O M AT E D D R I V I N G .                                        AC TIV E EQUAL S SAFER AND           the road condition, for example by     body movement on curves requires
                                                                                      M O R E C O M F O R TA B L E      anticipating bumps or potholes, and    high damping force. Driving over
                                                                                                                        change its settings accordingly.       slightly uneven surfaces only
Text: Martin Westerhoff                                                              Sven Greger, the man behind                                               requires a little. And safe contact
                                                                                 the wheel, chuckles with satisfac-        A damping system has to deal        between the tires and the ground
                                                                                 tion. He's a ZF research engineer      with a lot of situations. Uneven       requires moderate damping force.
                                                                                 who works on the basic develop-        tracks inevitably lead to direct      “A conventional shock absorber
                                                                                 ment of our semi-active and active     impact, which is cushioned by the      can only ever reach a compromise            ·
                                                                                                                                                                                                           ·
                                                                                                                                                               between sporty and comfortable,             ·

                                                                                                                                                               albeit a good compromise,” says             29
                                                                                                                                                                                                            ·
                                                                                                                                                               Dr. Christoph Elbers, vice president         ·
                                                                                 W HEN V EHIC L E DY N A MIC S T R IG GER                                                                                   ·
                                                                                                                                                               car chassis technology develop-
                                                                                 MOV EMEN T, SMO T ION K ICK S IN                                              ment at ZF.

                                                                                 Vertical axis
                                                                                 Lifting and lowering is the up
                                                                                 and down movement caused
                                                                                 by uneven road surfaces.

                                                                                                                                                                         See sMOTION on the proving
                                                                                                                                                                         ground – scan the QR code to
                                                                                                                                                                         watch the video.

                                                                                 Transverse axis
                                                                                 Pitching is when the vehicle                                                            Longitudinal axis
                                                                                 dips (when decelerating) or                                                             Rolling refers to the side tilt
                                                                                 rears up (when accelerating).                                                           caused by cornering.
THE E VOLUTION OF THE
    CDC DAMPING SYSTEM
                                                                   “sMOTION can actively                                              sMOTION
                                                                   pull up or push down the                                           No longer passive, but fully active – our shock absorber technology
    ZF's semi-active Continuous
Damping Control (CDC) system
solved the problem of these con-
                                                                   wheels.”
                                                                                                                                                                                                STANDARD TWIN-TUBE SHOCK ABSORBER
flicting objectives decades ago.
                                                                   DR. CHRISTOPH ELBERS
Our semi-active damping system
                                                                   Vice president car chassis technology development                                                                                The piston rod of the twin-tube shock absorber is
went into volume production for
                                                                                                                                                                           PISTON ROD           attached to the car body, and its casing is attached
passenger cars in 1997. Using the
                                                                                                                                                                                                to the steering knuckle. In the casing is a second pipe
signals from two wheel and body
                                                                                                                                                                                                completely full of oil, which is the working chamber.
sensors for each spatial axis, plus
                                                                                                                                                                                                The piston moves inside this cylinder. The distance
additional information such as
                                                                                                                                     CO M P E N S AT I N G                                      between the inner pipe and the casing serves as a
vehicle speed, lateral acceleration
                                                                                                                                            CHAMBER                                             compensating chamber. This is not completely full
and steering angle stored in a con-          on conditions. But in highly auto-                 P O W E R F U L A C T U AT O R S
                                                                                                                                                                                                of oil, since it has to be able to accommodate the oil
trol unit, the system continuously           mated or autonomous vehicles, all                    FOR A SMOOTH RIDE
                                                                                                                                                                                                displaced from the working chamber when the piston
monitors driving conditions and              the occupants become passengers.                                                                                            P I S T O N VA LV E
                                                                                                                                                                                                rod goes down. The bottom of the working chamber
calculates the optimum damping              “And in that scenario, every vibra-                 sMOTION can actively adjust
                                                                                                                                             WORKING                                            and the piston contain valves that restrict the oil
force for each wheel. The shock              tion, impact, roll or pitch simply            movements occurring at a frequency
                                                                                                                                             CHAMBER                                            flow more on the rebound direction (when the piston
absorber has either one or two               stops people from reading or                  of up to 5 Hertz – the equivalent of                                          BOT TOM
                                                                                                                                                                                                comes up) than in the compression direction (when
electronically controlled solenoid           working. This causes dispositions             0.2 seconds of vibration. In our test                                         VA LV E
                                                                                                                                                                                                the piston goes down). When the piston rises, it sucks
valves that can change the oil flow          known as motion sickness, making              vehicle, these adjustments are made
                                                                                                                                                                                                oil out of the compensation chamber back into the
in milliseconds to adjust the damp-          these activities impossible,” says            by a 2.5 kW actuator on each wheel.
                                                                                                                                                                                                working chamber.
ing hardness. ZF chassis expert              Dr. Elbers. “This effect is amplified         It's an electric pump that increases
Dr. Elbers explains: “sMOTION                by innovative seat arrangements               the oil pressure either above or
takes things a step further. Using           in which driver and passengers                below the shock absorber piston                             C D C VA LV E S                                                                                        ·
                                                                                                                                                                                                                                                              ·
the basic design of our tried-               may no longer have a view in the              and therefore actively moves it. For                                                                                                                               ·

and-tested CDC, we developed a               direction of travel.” A remedy can            high-frequency excitations – such as                                                                 TWIN-TUBE SHOCK ABSORBER WITH CDC                             31
                                                                                                                                                                                                                                                               ·
damper that can actively pull up             only be found in an active chassis.           manhole covers, cross joints, rough                                                                                                                                 ·
                                                                                                                                                                                                                                                               ·
or push down the wheel.”                     sMOTION is a ZF solution for the              asphalt or gravel – the sMOTION                                                                         A shock absorber with Continuous Damping Control
                                             future that is already improving              shock absorber has a bypass that                                                                     (CDC) uses either one or two electrically controlled
    Until now, vehicle body exci-            driving comfort today. Practically            reverts to the CDC solenoid valves.                                                                  solenoid valves. The CDC valves are used to vary the
tation was tolerated or even desir-          undisturbed by the driving process,                                                                                                                hydraulic resistance continuously. Low resistance
able to a certain degree so as to            passengers can spend their travel                 Dr. Achim Thomä, technical                                                                       produces soft damping; high resistance produces hard
give drivers perceptible feedback            time working or relaxing.                     project manager for sMOTION,                                                                         damping.
                                                                                           found himself and his team con-
                                                                                           fronted with an unusual challenge.
                                                                                           How could they convey the sys-
                                                                                           tem's effectiveness if it stopped
                                                                                           excitation so unobtrusively that
                                                                                                                                                                                    CDC         TWIN-TUBE SHOCK ABSORBER WITH SMOTION
                                                                                           passengers could barely feel a
                                                                                                                                                                                    VA LV E S
sMOTION actively counteracts side tilt when cornering. The key                             thing? The solution was simple.
                                                                                                                                                                                                    The sMOTION shock absorber has an electric pump
to autonomous driving is a beautifully undisturbed vehicle body.                           For demonstration purposes, Sven
                                                                                                                                                                                                that pumps the oil from the upper working chamber to
                                                                                           Greger now uses a tablet to control
                                                                                                                                                                                                the lower chamber or vice versa. This produces active
                                                                                           the shock absorbers on a stationary
                                                                                                                                                                                                force. A bypass upstream of the pump makes it possible
                                                                                           vehicle: individually, in pairs, or all
                                                                                                                                                                                                to activate two CDC valves to deal with frequencies
                                                                                           four at once. As he taps the screen,
                                                                                                                                                                                                above 5 Hertz.
                                                                                           the van lifts and lowers, pitches,
                                                                                           rolls and shakes like a rodeo horse,
                                                                                           at which point the engineers in the
                                                                                           seats have every reason to cling to
                                                                                           the handles despite the fact the car       ELEC TRIC MOTOR
                                                                                           is not going anywhere!                     AND PUMP UNIT                                                          Fascinated by shock absorbers?
                                                                                                                                                                                                             Simply scan this QR code for more information.
CLEAN AIR AND EFFICIENCY GO
                                                                                                                                         E L E C T R I F I E D, A U T O N O M O U S
                                                                                                                                         COMMERCIAL VEHICLES HOLD
                                                                                                                                         OUT THE PROMISE OF SAFE,
                                                                                                                                         ZERO-EMISSION DRIVING. WITH
                                                                                                                                         E XISTING STEERING SYSTEMS,
                                                                                                                                         HOWE V ER, THIS IS MORE OF A
                                                                                                                                         FA N TA S Y. S O W E ’ R E D E L I G H T E D
                                                                                                                                         TO INTRODUCE ZF’S PROTOT YPE
                                                                                                                                         FOR AN ELEC TROMECHANICAL
                                                                                                                                         STEERING SYSTEM. A WORLD
                                                                                                                                         F I R S T.

                                                                                                                                         Text: Achim Neuwirth

                                                                                                                                                                                                       A BIG WIN
                                                                                                                                                                                                     FOR EFFICIENCY

                                                                                                                                                                                                  But the environmental compat-
                                                                                                                                                                                             ibility of this steering system goes
                                                                                                                                                                                             beyond driving features alone; even
                                                                                                                                                                                             the technology itself is eco-friendly.
                                                                                                                                                                                            “Based on its first test drives in        ·
                                                                                                                                                                                                                                      ·
                                                                                                                                                                                             trucks, ReAX EPS operates up to          ·

                                                                                                                                                                                             15 percent more efficiently than our     33
                                                                                                                                                                                                                                       ·

                                                              T
                                                                                                                                                                                             most advanced electro-hydraulic           ·
                                                                                                                                                                                                                                       ·
                                                                        he electric drive purrs        our Electrically Powered Steering            adjusted. “In line with ZF’s guiding     system to date,” says Schulz. What’s
                                                                        quietly until the vehicle      (EPS) makes the electrification and          principle, See – Think – Act, ReAX       more, it’s much lighter. This weight
                                                                        comes to a standstill. The     automation of commercial vehicles            EPS is a critical system component       reduction, as well as its compact
                                                                        only sound that follows        a whole lot easier. “ReAX EPS even           for enabling trucks and buses to         design, is due to dispensing with
                                                              is rubber on asphalt as the front        has the potential to allow autono-           act,” says Schulz, who goes on to        the pump system, which means
                                                              wheels turn while parking. As if by      mous vehicles to maneuver without            explain in more detail. “Networked       that it has no need for a fossil fuel
                                                              magic, the steering wheel turns all      a mechanical link between the steer-         with cutting-edge control electron-      drive. Since a diesel engine always
                                                              by itself. This is a familiar scenario   ing wheel and steered wheels,” says          ics such as the ZF ProAI central         has to be running for servo-assisted
                                                              to drivers of hybrid and electric        Schulz.                                      computer and with environmental          electro- hydraulic steering systems,
                                                              passenger cars equipped with ZF                                                       sensors and other vehicle systems,       they are unsuited for full hybrids and
                                                              technology.                              I N T E L L I G E N T LY N E T W O R K E D   the intelligent steering system can      purely electric drives. ReAX EPS, on
                                                                                                                WITH THE FUTURE                     handle many tasks, ranging from          the other hand, has two advantages
                                                                  This, however, is different: the                                                  lateral control to SAE Level 4 auto-     in this respect. First, its actuator
                                                              vehicle is a truck. ZF has transferred       Steering a 40-ton truck without          mated driving.” This means that          is designed for an electric vehicle
                                                              its system expertise in passenger        a direct mechanical link or a hydrau-        a truck can steer itself on certain      drive. Second, the steering system
                                                              car steering technology to commer-       lic pump system? Unthinkable. Until          sections of the highway or in load-      itself requires so little installation
                                                              cial vehicles. The outcome – at the      now. But ReAX EPS has an electric            ing areas so the driver can work on      space that it allows greater design
                                                              same time a world first – is ReAX        motor with a maximum torque                  other activities or rest. ReAX EPS is    freedom for the components elec-
                                                              EPS, an electromechanical steering       of 70 Nm to transfer the required            also perfect for platooning, where       trifying the vehicle’s driveline. The
                                                              system for trucks and buses. “ReAX       force to the steering mechanisms.            trucks are electronically coupled        first vehicles to benefit from ZF’s
                                                              EPS is the first all-electric steering   ZF has combined this motor, its              while driving, with minimal safety       steering innovation will no doubt
                                                              system for commercial vehicles to        control unit, the steering gear and          distances between them thanks to         be delivery trucks, since those with
 Lower energy consumption, lower weight and less space:       hit the market,” says Mitja Schulz,      the sensor system in a highly com-           the autopilot. In addition, it can be    combustion engines are likely to
 dispensing with the hydraulic pump makes ReAX EPS a highly   head of ZF’s CV Steering Systems         pact actuator unit. So the steering          used in Park Assist or Lane Keeping      soon be banned from certain city
 efficient, flexible-use system.                              Business Unit. Currently a prototype,    can be electronically controlled and         Assist features.                         centers.
NEW HEIGHTS
                                                                                               “By working with technology leaders
                                                                                                such as Baidu or automotive manu-
                                                                                                facturers like Chery, we gain deep
              MA JOR CHINESE
                                                                                                insights into the market that is set
              C O R P O R AT I O N S A R E
                                                                                                to determine the future of the global
              W O R K I N G I N T E N S E LY
                                                                                                economy. China could soon be our
              ON THE TECHNOLOGIES
                                                                                                most important market, and we’re
              O F T O M O R R O W. O N E O F
                                                                                                well prepared for that,” says Qi.            But state subsidies and regula-
              THEIR KEY FOCUSES IS
                                                                                                                                         tions are not the only factors behind
              ARTIFICIAL INTELLIGENCE

                                                       S
                                                                                                    STRONG GROW TH IN                    the AI explosion. Given its large
              (A I). ZF A ND CHINESE
                                                                 lowly but surely, the taxi       ARTIFICIAL INTELLIGENCE                population, China also has a huge
              T E C H N O L O G Y C O M PA N Y
                                                                 carves its way through                                                  volume of data at its disposal, pro-
              BAIDU ARE WORK ING
                                                                 the maze of cars, mopeds          One particular technology is          viding artificial intelligence with
              T O G E T H E R T O A C C E L E R AT E
                                                                 and buses in stop-and-go      drawing the attention of developers       the information it needs in order to
              THE DE VELOPMENT OF
                                                       traffic. The taxi passes miles of       in Shenzhen and all over China. It is     advance. On top of this, the country
              AUTONOMOUS DRIVING
                                                       factory buildings and giant ware-       so important that it has even been        draws on its concentrated knowl-
              CONCEPTS.
                                                       houses, and it’s hard to believe that   given a major role in the national        edge of digitalization.
                                                       just 40 years ago the city of Shen-     five-year plan: artificial intelligence
                                                       zhen was still a sleepy fishing vil-    (AI). The Chinese government is              “Artificial intelligence is intriguing
              Text: Friederike Pater
                                                       lage just outside Hong Kong. Today,     sure that AI will shape the future.       to me as it can be used in so many          ·
                                                                                                                                                                                     ·
                                                       the cityscape is dominated by glass                                               areas of life and can even improve it.      ·

                                                       skyscrapers nosing up through a             A study by market research com-       Last but not least, it also offers solu-    35
                                                                                                                                                                                      ·
                                                       layer of smog. The buildings bear       pany Gartner backs this up. Gart-         tions for the mobility of the future,”       ·
                                                                                                                                                                                      ·
                                                       the names of Chinese technol-           ner analysts place the global busi-       explains Dr. Xing Yuan, general man-
                                                       ogy giants: Huawei, Tencent, ZTE,       ness value of artificial intelligence     ager of series production and com-
                                                       Dingoo.                                 in 2018 at $1.2 trillion, an increase     mercialization at Baidu. “Our goal is
                                                                                               of 70 percent compared to 2017.           to promote AI technology and make
                                                              D I G I TA L I Z AT I O N ,      According to forecasts, the figure        it practical for everyday life.”
                                                             MADE IN SHENZHEN                  will rise to $3.9 trillion within the
                                                                                               next four years.                           RESE ARCH IN HOMEGROWN
                                                           No other city demonstrates                                                         A I L A B O R AT O R I E S
                                                       China’s digital evolution as well as                B I G D ATA
                                                       Shenzhen. It has become the heart                IS BOOSTING AI                       Baidu has been working in part-
                                                       of China’s nationwide digitalization                                              nership with ZF since 2017. Along
                                                       overnight and is churning out tech-         While it’s true that the US is the    with Alibaba and Tencent, it forms
                                                       nological innovations at a breath-      birthplace of artificial intelligence,    part of the corporate triumvirate
                                                       taking pace. ZF is already a part       China too has become an AI epicen-        known as “BAT,” which represents
                                                       of this unique ecosystem. “Here in      ter. By 2025, it will be closing in on    a kind of digital parallel universe in
                                                       China, we march to the beat of a        North America and within another          China. Baidu, once a search engine
                                                       different drum; everything has to be    five years will be market leader.         developer and operator, has become
                                                       faster, higher, more advanced,” says    A study by auditing and consulting        the Chinese equivalent of Google
                                                       Qi Ping, head of development at ZF      firm PwC estimates that China’s           and Wikipedia. Today, it’s also the
                                                       China. “It is fascinating to see how    GDP will rise to the equivalent of        leading provider of high-resolution
                                                       quickly ideas can turn into series      $7 trillion by 2030 purely on the         maps. Online retailer Alibaba started
                                                       products.” The spirit of innovation,    back of AI. As a comparison, for          out as a kind of Chinese eBay and
                                                       the fast pace and an unquenchable       North America PwC predicts a GDP          has developed into an Amazon-like
                                                       thirst for progress makes Chinese       increase of about 15 percent, to          e-commerce giant in no time. Ten-
                                                       companies valuable partners.            $3.7 trillion.                            cent dominates instant messaging
services with its WeChat platform              Baidu’s high-resolution maps
“Here in                                  and is also a leader in the gaming         are making a major contribution to
                                          sector. All three companies now            autonomous driving. Modern sen-
China, we                                 have their own “AI Labs” in which          sor technology in special vehicles                                        SPEAKER’S CORNER
                                          they explore the universe of artificial    records the global road networks and
march to                                  intelligence.                              provides the data for high-definition
                                                                                     (HD) maps. However, updating the
the beat of                                   China has become a pioneer in          entire traffic infrastructure on a daily
                                                                                                                                                                               Erik Figenbaum is a researcher at the Norwegian
                                                                                                                                                                                  Institute of Transport Economics (TØI) in Oslo,
                                          alternative concepts of mobility. The      basis is near-impossible. To remain
a different                               government’s next goal is to set the       in the game, Baidu had to find the
                                                                                                                                                                                  an independent and privately owned research
                                                                                                                                                                                                 institute based on a foundation.
                                          global standard for the autonomous         right partner. “Cooperation between
drum;                                     cars of the future. It intends to net-     a digitization company such as Baidu
                                          work intelligent vehicles with a view      and an established automotive sup-
everything
                                                                                                                                Electrified Nation
                                          to reducing accidents and emissions        plier like ZF allows the strengths of
                                          by 30 percent and 20 percent               each company to come to the fore, to
has to                                    respectively by 2025.                      the customers’ benefit,” comments
                                                                                     Dr. Xing Yuan, and adds: “ZF is the
be faster,                                    COMBINED STRENGTHS                     perfect partner for us, and its super-
                                                                                                                                F O R Y E A R S N O W, N O R WAY H A S B E E N G AT H E R I N G E X P E R I E N C E W I T H E L E C T R I C V E H I C L E S O N
                                                                                                                                A L A R G E S C A L E . H O W D O E S E - M O B I L I T Y W O R K I N T H I S N O R D I C C O U N T R Y, A N D H O W C A N
                                                                                     computer ZF ProAI is an excellent
higher, more                                 “AI is a game changer, and autono-      product.” ZF ProAI is an AI-capable
                                                                                                                                T H I S B E T R A N S F E R R E D T O O T H E R C O U N T R I E S? A N A S S E S S M E N T.

                                          mous driving is the future of mobility.    vehicle computer with a wide range
advanced.”                                And we want to be part of that from        of configuration options.                       Norway is the global leader in electric vehicle adop-        from charging loads. 94 percent of Norwegian BEV own-
                                          the outset,” says Xing Yuan, explain-                                                 tion per capita. More than eight percent of the cars in the       ers charge at home in their own parking space, and many
QI PING                                   ing Baidu’s transformation into an            ON A COMMON MISSION                     national fleet are rechargeable. Two-thirds are battery           only drive locally, hence getting by with home charging.
Head of development, ZF China             AI specialist. “Autonomous driving                                                    electric vehicles (BEVs); the rest are plug-in hybrids
                                          presents the perfect challenge when           Chinese car-sharing operator            (PHEVs). Since the 1990s, Norway has been supporting                  On long-distance trips, users will of course need to
                                          it comes to the use of artificial intel-   Pand’s electric vehicles are already       the BEV market through exemptions in purchase tax, road           recharge – unlike diesel car owners, who can fill up for the
                                          ligence. And we are focusing on use        being tested with the ZF-Baidu tech-       toll, parking charges, and by bus lane access. PHEVs have         entire trip. It will be expensive to operate a fast-charging
                                          of the technology in the automotive        nology, and some Chinese cities will       fewer incentives, but are more attractive than diesel vehi-       infrastructure meeting all needs for long-distance driving
                                          sector. Our goal is to commercialize       soon allow autonomous vehicles to          cles. Together, they facilitate a gradual shift to e-mobility.    on peak travel days. On-street charging is another big
                                          Al for volume production.”                 be tested on public roads.                                                                                   challenge inhibiting BEV ownership in densely populated
                                                                                                                                    The substantial tax exemptions have made BEVs the             cities. The municipality of Oslo has installed chargers
                                                                                                                                cheapest vehicles to buy, and this advantage becomes              in parking lots and on streets, but struggles to keep up
                                                                                                                                directly visible in the sales price. Multi-vehicle families,      with the demand. Other mobility services could act as
                                                                                                                                the main adopters, find BEVs economical to use and face           supportive measures preserving mobility in crowded city
                                                                                                                                only few barriers. They park and recharge their BEV on            centers. Battery life is not yet an issue in Norway – maybe,
                                                                                                                                their own land, and can use their other vehicle for driving       because our summers are not that hot. Heat, however,
                                                                                                                                long distances. If other countries are able to reach the          is the main factor in degrading battery life. When the
                                                                                                                                same group with suitable incentives, a market pull will be        battery capacity decreases, BEVs will most likely continue
T HE T HR EE CHINE SE A I GI A N T S : DID YOU K NOW ?                                                                          created, leading to a steep increase in BEV adoption.             to be used by less-demanding users until the end of the
                                                                                                                                                                                                  vehicle life. Then the batteries are handed in for recycling,
                                                                                                                                    But Norway has other favorable conditions. Diesel is          organized by the vehicle importers, and subsidized by a
                                                                                                                                expensive, and electricity is cheap with 98 percent based         300 -euro scrappage bonus.
                                                                                                                                on emission-free hydropower, so the emission benefit
Baidu                                     Alibaba                                    Tencent                                    is huge. This benefit has also been realized at EU level,             Norway has proven that BEVs can sell well in a mass
The Beijing-based group operates the      Chinese internet conglomerate Alibaba      With brand equity of $178 billion,         as electricity production is part of the EU greenhouse            market, and that the vehicles can easily be integrated
eponymous search engine Baidu. In         Group is home to 12 brands. One of the     Tencent currently ranks fourth among       gas emission trading system, whereas transportation is            into the overall vehicle fleet by multi-car households. The
the first quarter of 2018, the company    most successful is the mobile payment      the world’s most valuable brands. The      not. Low superhighway speed limits in Norway reduce               Norwegian e-mobility incentives have created a powerful
generated revenue of approximately        service Alipay, run by group subsidiary    group operates in a diverse range of       energy consumption and preserve the range, whereas                bottom-up market pull, whereas governments in coun-
$3.33 billion. Baidu is not afraid to     Ant Financial, currently the most          business areas from instant messaging      cold winters reduce the range by 25 percent compared              tries like Germany focus more on policies creating a top-
experiment, and is constantly expanding   valuable fintech company in the world.     to social media and online gaming.         to summer driving. The Norwegian grid is robust enough            down market push. The bonus to German BEV buyers
into new business areas – from meal       Its main sources of sales are B2C and      WeChat is the most popular messaging       to handle charging, as we use electricity for space heat-         introduced last year seems less effective than originally
delivery services, to online payment      B2B e-commerce platforms Alibaba.com       service in China, with a billion users.    ing. Countries with less robust grids will need policies          expected and may therefore need to be increased in order
providers, to tomorrow’s autonomous       and AliExpress.                                                                       that are capable of cushioning electricity peaks resulting        to have a real impact on their purchasing behavior.
driving.
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