ZF hybrid transmission for heavy trucks in real-world testing

ZF’s new TraXon 2 Hybrid transmission is now proving its capabilities in real-world conditions. In recent public road tests, European transport fleets and members of the German Association for Freight Transport, Logistics and Waste Disposal (BGL) e.V. were able to experience the system firsthand in ZF’s own test vehicle.

Early evaluations have been positive, with tests confirming that the hybrid technology can significantly reduce emissions and lower Total Cost of Ownership (TCO), while meeting the operational demands of modern fleets.

“The long-term and tangible added value for manufacturers and fleets through the newly developed TraXon 2 Hybrid is clear. That’s why we believe the hybrid powertrain will become an important technology for commercial transport,” said Christian Feldhaus, VP of the transmissions and hybrids product segment at ZF’s Commercial Vehicle Solutions Division.

“In applications with high daily mileage, the classic long-haul truck needs a pragmatic and charging infrastructure independent solution. The hybrid powertrain will enable OEMs and fleets to achieve their CO2 reduction targets, while also delivering a strong economic business case in terms of cost-effectiveness,” he added.

The TraXon 2 Hybrid was developed to improve overall efficiency and significantly reduce CO2 emissions while preserving the range and refueling capabilities of the combustion engine. The transmission system which ZF presented during last year’s IAA Mobility Show is suitable for heavy commercial vehicles as a full hybrid or plug-in hybrid. Its versatility allows seamless integration into various vehicle architectures. It can also be combined with diesel, HVO/e-fuels, CNG/LPG or hydrogen combustion engines.

Calculations using the VECTO simulation tool show a CO2 reduction potential of up to 47 per cent in long-haul transport and up to 73 per cent in distribution transport, with consistent recharging. This directly addresses fleet targets set for 2030 and creates flexibility regarding future toll and tax regulations.

Accordingly, ZF also supports the call for the classification of PHEV trucks within European toll systems, including total weight compensation, to be similar to what is already implemented for electric trucks.

The new system is technically based on ZF’s proven large-scale production technology. At its core is the TraXon 2 transmission for heavy commercial vehicles, complemented by in-house developments in various electrification areas. The electric motor is positioned in the so-called P2 layout between the clutch and transmission, transmitting its power via a planetary gear directly to the input shaft. This allows the truck to drive purely electrically.

Additionally, the e-motor supports the combustion engine in boost mode or enables regenerative braking. The electrical architecture operates at 600 to 800 volts, with a continuous power output of 190 kW, and a significantly higher peak power.