ZF, a global vehicle technology supplier, has launched a new high-voltage testing facility near Solihull, UK, designed to validate 800V electric vehicle systems. The laboratory, partially funded by the Advanced Propulsion Centre (APC), will be available for both internal use and third-party testing.
“OEMs want the compelling benefits of 800V but finding facilities capable of validating these higher-rated systems has not been easy,” said Adrian Mitcham, Head of Special Applications at ZF.
The 46-square-metre facility can accommodate various components, from small modules to full electric drive truck axles. The laboratory features safety measures including an interlocked monitored door and active discharge resistance systems. Its power supplies can handle 1,500V DC at 45kW, with potential expansion to 90kW.
The facility has begun testing projects for ZF’s global development teams, including validation of a fuel cell air compressor and hydrogen recirculation blower for commercial vehicles. The site will also support the Institution of Mechanical Engineers (IMechE) with high-voltage training programmes.
Current electric vehicles typically use 400V systems, requiring approximately 20 minutes of charging time for 200 kilometres of range. According to ZF, 800V systems could reduce this charging time by half and allow for lighter wiring. When combined with Silicon Carbide MOSFETs, the company states these systems could achieve up to 10% efficiency improvements.
The laboratory has received several national, international, and customer accreditations for work with tier-one suppliers and OEMs. Additional space has been allocated for potential future expansion of the facility.
