ZF's hybrid transmission for heavy-duty trucks completes real-vehicle testing

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Real vehicle verification: The plug-in hybrid solution for ZF heavy-duty trucks has passed the on vehicle testing of European fleets and the German BGL Association (Federal Association for Freight, Logistics and Environmental Services). Hybrid technology can significantly reduce carbon dioxide emissions while balancing cost-effectiveness. The vehicle's range is not affected and the existing fuel supply facilities can continue to be used.

The TraXon 2 Hybrid, a second-generation hybrid transmission from ZF, has demonstrated its outstanding performance in actual vehicle tests. In recent public tests, European transport fleets and members of the German BGL association personally experienced the system through ZF test vehicles, and received positive initial feedback. The test results confirm that this hybrid technology can significantly reduce emissions and lower the total cost of ownership (TCO) of vehicles, while meeting the daily operational needs of modern fleets.

ZF's hybrid transmission for heavy-duty trucks completes field testing

Christian Feldhaus, Vice President of Transmission and Hybrid Products at ZF Commercial Vehicle Solutions Division, said, "The long-term practical value that ZF's TraXon 2 Hybrid, the second-generation new hybrid transmission, brings to vehicle manufacturers and fleets is evident. We believe that hybrid powertrain will become a key technology in the field of commercial vehicle transportation. For application scenarios with long daily driving distances, typical long-distance transport trucks require a practical solution that does not rely on charging infrastructure. Hybrid powertrains can not only help vehicle manufacturers and fleets achieve their carbon dioxide emission reduction goals, but also build strong advantages in terms of cost-effectiveness. ”

Roger Schwarz, head of the technical working group at the German BGL Association, added, "The high efficiency, reliability, and sustainability of this technology are crucial for the development of our industry. Prior to the widespread adoption of charging infrastructure in Europe, the hybrid system showcased by ZF provides our member companies with a practical solution towards full electrification

TraXon 2 Hybrid, the second-generation new hybrid transmission from Chuansheng

The development of the TraXon 2 Hybrid, a second-generation hybrid transmission from ZF, aims to improve overall efficiency and significantly reduce carbon dioxide emissions, while retaining the range advantage and fuel supply convenience of internal combustion engines. The gearbox made its debut during the 2024 International Transport Expo (IAA) and is suitable for heavy-duty commercial vehicles. It can be configured as a full hybrid or plug-in hybrid. Excellent compatibility enables seamless integration into various vehicle architectures, allowing for flexible adaptation to diesel, hydrogenated vegetable oil (HVO)/synthetic fuels, compressed natural gas (CNG)/liquefied petroleum gas (LPG), or hydrogen internal combustion engines.

By using VECTO simulation tool to calculate emissions reduction while considering cost-effectiveness, this technology can achieve up to 47% carbon dioxide emissions reduction in long-distance transportation scenarios and up to 73% in distribution transportation scenarios under continuous charging. This performance can directly support the fleet's 2030 emission reduction targets and provide flexibility for dealing with future toll and tax regulations. Therefore, ZF calls for and supports the inclusion of plug-in hybrid electric (PHEV) heavy-duty trucks in the European toll discount system, and provides total mass compensation based on existing policies for electric trucks.

Mature mass production technology ensures stable performance. This new hybrid transmission system is developed based on ZF's mature large-scale production platform. The core product of this platform is the TraXon 2, a second-generation transmission suitable for heavy-duty commercial vehicles, supplemented by multiple electrification technologies independently developed by ZF. The motor adopts a P2 layout, located between the clutch and the gearbox, and transmits power directly to the input shaft through planetary gears, achieving pure electric drive for the truck. In addition, the motor can also provide support for the internal combustion engine in assist mode or achieve regenerative braking to recover energy. The working voltage of this electrical architecture is 600 to 800 volts, with a continuous output power of 190 kilowatts and significantly higher peak power.