ZF has opened the UK’s first-of-its-kind hazardous voltage Test & Validation Laboratory at its R&D hub near Solihull. The main aim is to accelerate the adoption of 800V architectures with improved efficiency, charging and vehicle performance advantages for EVs.
Partially funded by the Advanced Propulsion Centre (APC), the 800V test and validation facility will offer ZF and its customers specialist hazardous voltage testing capacity. ZF will offer validation testing to third parties and the facility already holds several national, international and customer accreditations to work with Tier 1 suppliers and OEMs.
“OEMs want the compelling benefits of 800V but finding facilities capable of validating these higher-rated systems has not been easy,” said Adrian Mitcham, head of special applications at ZF.
Presently, most EVs are based on 400V architectures and need approximately 20 minutes of charging for 200km of range. An 800V EV would only need half that time; and 800V systems unlock further efficiencies such as lower gauge and therefore lighter wiring. When combined with silicon carbide MOSFETs, efficiency gains up to 10% are possible. This could result in downsized batteries or improved vehicle range.
ZF has developed a modular inverter architecture that enables flexibility in both 400V and 800V voltage classes. The facility is now ramping up testing for ZF’s global product development teams. One of the first developments tested was for truck and bus applications, with ZF’s Commercial Vehicle Solutions (CVS) division using the facility to validate a new fuel cell air compressor for the segment.
The laboratory is ZF’s first dedicated facility and one of just a handful in the UK. Measuring 46m2 , the unit can accommodate anything from the smallest modules to a full e-drive truck axle. It was designed from the ground up with safety as priority.
An interlocked and monitored door ensures the entire laboratory forms a secure safety cell. Several other safety measures have been undertaken as part of the installation, including active discharge resistance to remove hazardous energy as quickly as possible. The facility has also been designed with future expansion in mind.
The site will also be made available for academic projects and is already supporting the Institution of Mechanical Engineers’ (IMechE) HV training.