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ZF has launched an 800V Test & Validation Laboratory at its R&D Hub near Solihull, aimed at advancing next-generation electric vehicle (EV) technologies. The new facility will help accelerate the adoption of 800V architectures, offering improved efficiency, faster charging, and enhanced vehicle performance. The site is partially funded by the Advanced Propulsion Centre (APC) and will support ZF, third-party clients, and academic projects.
Key Highlights:
- First 800V Test Lab by ZF in the UK, partially funded by APC.
- Focuses on improving efficiency, charging times, and performance for next-gen EVs.
- Offers validation testing to OEMs, tier-one suppliers, and third parties.
- Supports IMechE high-voltage training for future engineers.
ZF’s 800V Test & Validation Laboratory is the first of its kind for the company in the UK. It aims to promote the adoption of 800V systems, which provide substantial efficiency gains, including reduced charging times and lighter, more efficient wiring compared to 400V systems. This shift can lead to smaller batteries or extended range for electric vehicles.
Partially funded by the APC, the new laboratory will provide ZF and its customers with specialist hazardous voltage testing capacity, helping to roll out and validate the benefits of 800V technology. The site is also open to third-party testing, and already holds several national and international accreditations, making it well-equipped to work with tier-one suppliers and OEMs.
Adrian Mitcham, Head of Special Applications at ZF, stated, “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.”
The new facility’s capabilities include testing a wide range of components, from small modules to full E-drive truck axles. Safety was a primary focus during the design, featuring an interlocked and monitored door, active discharge resistance for hazardous energy, and optically isolated instrumentation. The laboratory also has room for future expansion, with the ability to handle 1,500V DC at 45kW, expandable to 90kW if needed.
The facility has already begun work on several projects, including testing a fuel cell air compressor and a Hydrogen Recirculation Blower for ZF’s Commercial Vehicle Solutions division. The 800V Test & Validation Laboratory will also support academic initiatives, including providing high-voltage training for engineers through the Institution of Mechanical Engineers (IMechE). By enabling practical training opportunities, ZF aims to help ready the next generation of engineers to work safely on advanced electric vehicle systems.
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