ZF opens 800V Test & Validation facility in the UK

New facility enhances 800V adoption and provides testing services for electric vehicle innovations.

Solihull, United Kingdom- ZF Friedrichshafen AG., recently opened the UK’s first HV Test & Validation Laboratory at its R&D Hub near Solihull. This facility aims to accelerate the adoption of 800V architectures, enhancing efficiency, charging, and vehicle performance for electric vehicles (EVs). Partially funded by the APC, the laboratory provides essential hazardous voltage testing capacity for ZF and its customers.

To enable more next-generation mobility projects to take advantage of the benefits of switching to 800V, ZF will also offer validation testing to third parties. The facility already holds several national, international and customer accreditations to work with tier-one suppliers and OEMs.

Mr. Adrian Mitcham, Head of Special Applications at ZF, said, “OEMs want the compelling benefits of 800V but finding facilities capable of validating these higher-rated systems has not been easy. Just like our world-class EMC and climatic chambers on the same site, we plan to offer 800V validation services to external organisations so that more of the benefits can be realised in the wider mobility sector.”

Most EVs currently operate on 400V architectures, requiring about 20 minutes to add 200 kilometers of range, while 800V systems cut that time in half. These systems offer additional efficiencies, such as lighter wiring and potential 10% efficiency gains when combined with Silicon Carbide MOSFETs, leading to smaller batteries or improved range.

ZF has developed a scalable, modular inverter architecture for both 400V and 800V systems, and the facility is ramping up testing for its global product development teams. One of the first applications tested was for trucks and buses, including a new fuel cell air compressor validated by ZF’s Commercial Vehicle Solutions division. Recently, they also validated a Hydrogen Recirculation Blower, unveiled at IAA Transportation 2024.

The 800V Test & Validation Laboratory is ZF’s first dedicated facility of its kind in the UK, spanning 46 square meters and capable of accommodating anything from small modules to a full E-drive truck axle. Designed by ZF’s HV team with a focus on safety, it features an interlocked and monitored door to create a secure safety cell, along with active discharge resistance for quick energy removal during emergencies and optically isolated instrumentation access.

The facility is designed for future expansion, with additional floorspace available and infrastructure capable of handling up to 1,500V DC at 45kW, expandable to 90kW. It will also support academic projects and is actively involved in the Institution of Mechanical Engineers (IMechE) HV training, preparing UK engineers to work safely with such systems.