ZF is equipping NIO’s flagship electric vehicle, the ET9, with its latest generation steer-by-wire system. The technology Group is supplying both the steering wheel actuator for steering and steering feel as well as the redundant steering gear actuator and associated software. The Smart Electric Executive Flagship model thus has no mechanical connection between the steering wheel and the front wheels. Since the creation of its “Chassis Solutions” Division at the beginning of 2024, ZF now has a comprehensive portfolio of purely electronically controlled steering and braking systems and controlled damping systems. In combination with ZF’s own cubiX software, these technologies form the basis for the software-defined vehicle.
“We are supplying customers with the steering of the future. With our production-ready steer-by-wire steering system, we are launching the era of the software-defined vehicle. With an entire portfolio of innovative by-wire technologies, we are a sought-after supplier and a key driver of future-oriented chassis technologies,” says Dr. Peter Holdmann, Member of the Board of Management at ZF and responsible for the Chassis Solutions Division. “ZF is firmly establishing itself as a technology leader in this area and giving car manufacturers such as NIO new freedom in terms of design, safety, comfort and driving functions.”
“At NIO, we are committed to delivering groundbreaking innovations that redefine premium driving experience. Steer-by-wire technology is a key enabler of software-defined vehicles, offering enhanced driving comfort, uncompromised dynamics, and future-proof technology,” says Danilo Teobaldi, Principal Chief Engineer at NIO.
“Our collaboration with ZF, a globally recognised leader in high-quality automotive solutions, is a testament to our ambition to set new industry benchmarks by deploying our smart EVs on a global-market stage.
Since the strategic partnership we signed with ZF in 2022, to the industrialisation of this technology, we have demonstrated our ability to execute and deliver cutting-edge solutions. Together with ZF, we are shaping the future of intelligent and electrified mobility, setting new standards for the industry.”
Steer-by-wire steering: An advantage in your hands
ZF’s steer-by-wire steering system has a mechatronic actuator between the wheels as the only source of transmitting steering inputs. There is no mechanical connection between the steering wheel and steering gear. Steering commands are issued by a steering wheel actuator in the cockpit, which includes a corresponding angle of rotation sensor. An electric drive – the so-called torque feedback unit – reproduces the natural steering feel and feedback from the road. The ZF system adjusts the steering ratio individually so that the ratio of the steering wheel angle to the wheel angle is optimally adapted for different driving speeds or situations.
The technology enables possibilities for the development of new, more compact steering wheels that no longer require drivers to change their grip when parking. All in all, this leads to significantly better manoeuvrability, as the steering wheel angle is reduced when parking or during slow-driving manoeuvres. Combined with ZF’s own AKC mechatronic rear-wheel steering, this increases driving comfort significantly in electric vehicles with a longer wheelbase. Driving pleasure is maintained as the steering feel can be adjusted from sporty and direct to comfortable and relaxed. The removal of the physical steering column can help increase driver safety in the event of an accident.
ZF’s steer-by-wire technology is therefore a further development of electric power steering – ideally suited for electric and automated vehicles.
Division Chassis Solutions: Orders in key market regions
This latest steering technology is already in series production with another major global car manufacturer. Customer orders for the steer-by-wire system have also been won in Europe.
“The series application shows that our strategy is correct and successful. With a comprehensive product portfolio consisting of hardware and software with solutions for vehicle motion control in vertical, lateral and longitudinal dynamics, we provide our customers with system expertise from a single source. In this way, we are actively shaping the transformation towards the software-defined vehicle,” explains Holdmann.
In January 2024, the technology Group merged its Active Safety Technology and Car Chassis Technology divisions into one powerful unit to exploit the full potential of the future chassis business and continue to act as an innovation leader. This has created a new powerhouse in the industry.
As a direct result of this new divisional setup, ZF announced a major order for brake-by-wire braking systems at the beginning of the year: Almost five million vehicles from a leading global vehicle manufacturer will be equipped with ZF’s electromechanical braking technology.
With the most comprehensive range of by-wire technologies, ZF plays a leading role in the development and industrialisation of modern chassis systems that do not require mechanical connections or system fluids.