In a significant stride towards advancing the electric vehicle (EV) industry, ZF has unveiled the UK’s first dedicated 800V Test & Validation Laboratory at its R&D Hub near Solihull. Partially funded by the Advanced Propulsion Centre (APC), this state-of-the-art facility is designed to accelerate the development of next-generation electric vehicles by supporting higher-efficiency 800V architectures, an essential step in improving charging times and vehicle performance.
Pioneering a New Era of 800V EV Systems
The demand for 800V EV architectures has been growing steadily as automakers seek to enhance vehicle efficiency and reduce charging times. While most current EVs operate on 400V systems, 800V technology offers significant advantages, including halving the charging time needed to add 200 kilometers of range—from 20 minutes to just 10. Additionally, 800V systems allow for lighter wiring, contributing to overall vehicle weight reduction and, when paired with advanced silicon carbide MOSFETs, can boost efficiency by up to 10%. These improvements could result in downsized battery packs or increased range, benefitting both vehicle manufacturers and consumers alike.
However, the challenge lies in finding specialized testing facilities capable of validating these high-voltage systems. ZF’s newly launched Test & Validation Laboratory addresses this gap by providing industry-leading hazardous voltage (HV) testing capabilities for OEMs and tier-one suppliers.
“OEMs want the compelling benefits of 800V but finding facilities capable of validating these higher-rated systems has not been easy,” explained Adrian Mitcham, Head of Special Applications at ZF. “Our goal is to offer validation services that enable more organizations across the mobility sector to adopt and realize the advantages of this cutting-edge technology.”
Supporting Industry and Innovation
ZF’s facility is already ramping up its efforts, supporting not only internal projects but also offering validation services to third parties. With national, international, and customer accreditations in place, the lab is poised to play a key role in enabling more next-generation mobility projects to take advantage of 800V technology. One of the first projects to utilize the facility was the validation of a commercial vehicle fuel cell air compressor for ZF’s Commercial Vehicle Solutions (CVS) division. More recently, the lab was used to validate ZF’s new fuel cell Hydrogen Recirculation Blower, unveiled at the IAA Transportation 2024 event.
The facility’s capabilities are substantial. Spanning 46 square meters, it can accommodate components as small as individual modules or as large as full E-drive truck axles. Designed from the ground up with safety as a priority, the laboratory features an interlocked and monitored door system that ensures the space functions as a secure safety cell. Other safety measures include active discharge resistance to rapidly remove hazardous energy in case of emergencies, and optically isolated instrumentation to reduce the risk of electrical hazards.
Looking ahead, ZF’s Test & Validation Laboratory is also future-proofed. With infrastructure in place to handle up to 1,500V DC at 45kW and the capacity to increase this to 90kW if necessary, the facility is well-positioned to support even higher-voltage systems in the future. Adjacent space is also available for potential expansion, underscoring ZF’s commitment to staying at the forefront of electric mobility innovation.
Beyond serving the industry, ZF’s new facility will also support academic projects and future engineer training. Already, the site is actively involved in providing high-voltage training in collaboration with the Institution of Mechanical Engineers (IMechE), ensuring that the next generation of engineers is equipped with the skills to work safely with these advanced systems. As 800V architectures become more prevalent, this training will be critical in preparing the workforce for the challenges and opportunities that lie ahead in electric mobility.
ZF’s 800V Test & Validation Laboratory represents a key milestone in the electric vehicle revolution. By offering cutting-edge testing capabilities, supporting industry partners, and fostering future talent, ZF is helping to accelerate the adoption of 800V systems, driving the electric vehicle industry towards a more efficient and sustainable future. As automakers increasingly look to 800V architectures for their next-generation EVs, ZF’s facility in Solihull will play a crucial role in unlocking the full potential of this transformative technology.
