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Ultra-high-speed 30,000-rpm EV motor unleashes 3,500 Nm of torque at wheels

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Ultra-high-speed 30,000-rpm EV motor unleashes 3,500 Nm of torque at wheels

German automotive supplier ZF has developed a compact electric vehicle drive that spins at up to 30,000 rpm and delivers 3,500 Nm of peak torque at the wheels.

It uses a two-stage gearbox to turn the motor’s high speed into usable wheel torque, allowing it to shrink the drive while maintaining the same power output as a comparable unit.

The 3-in-1 system combines an electric motor, power electronics, and a transmission.

The version ZF presented delivers 200 kW of peak power and is nearly 25% smaller and lighter than a comparable drive that runs at 18,000 rpm. ZF is in talks with several automakers and is targeting production by 2030.

At a given power output, an electric motor spinning faster needs to generate less torque.

Since motor torque is closely tied to rotor volume, the higher speed allows ZF to use a smaller rotor and build a lighter motor. The transmission then reduces rotational speed and multiplies torque before it reaches the wheels.

ZF uses a two-stage transmission with helical gears and a reduction ratio of about 18:1.

That setup gives the High Revolution Drive its peak wheel torque of 3,500 Nm while letting the motor run at speeds well above those of the 18,000-rpm unit ZF used for comparison.

“The High Revolution Drive draws on ZF’s full systems expertise,” said Thomas Meiser, head of ZF’s E-Mobility Business Unit.

“Rather than optimizing individual components in isolation, we systematically coordinate the electric motor, power electronics and transmission,” he added.


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