Osegi
Automotive·2 min read

ZF High Revolution Drive: 30,000 rpm E-Motor Cuts Size and Weight

ZF's new 3-in-1 electric drive spins at up to 30,000 rpm, promising roughly 25 percent less space and weight and half the magnet mass of a current unit.

Compact 3-in-1 electric axle drive from ZF combining motor, inverter and gearbox in a single housing.
Image: Autos
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ZF has unveiled the High Revolution Drive, an electric axle drive whose motor turns at up to 30,000 rpm, nearly twice the speed of typical systems. Motor, inverter and gearbox share one housing, the 3-in-1 layout common in the industry. The supplier wants to save space, weight and magnet material from problematic supply chains without giving up efficiency.

Smaller, lighter, fewer magnets

ZF compares the design with a compact drive from its own Select platform that has identical output and reaches 18,000 rpm. Against it, the new unit is to take up almost 25 percent less space, weigh 25 percent less and use half the magnet mass. ZF gives no absolute dimensions, weights or definition of installation space. Pre-development engineer Stephan Demmerer said in an interview with VDI Wissensforum that he expects savings of about 22 kg on a drive that typically weighs 80 to 100 kg today.

The principle is simple: at equal power, a faster motor needs less torque at the shaft and can have a smaller rotor. A two-stage spur gearbox with an 18:1 ratio brings the speed down. The version shown delivers 200 kW peak power and 3,500 Nm of wheel torque; ZF publishes no continuous figures. The target is volume cars with 150 to 200 kW and 400 or 800 volt systems.

Open questions

ZF says efficiency matches the 18,000 rpm drive. Its product page cites up to 93 percent under WLTP and 13 percent lower system costs, though it is unclear whether the comparisons use the same system boundaries. High speeds stress rotor, bearings, cooling and gearing and add noise. Business unit head Thomas Meiser calls low noise and vibration hard development goals; ZF uses adapted tooth geometry and ribbed housings, and the prototype gets by with smaller bearings. Series suitability still has to be proven.

ZF does not name the magnet chemistry or how many rare earths are saved, so half the magnet mass does not mean half the dependency. BMW avoids magnets entirely with externally excited motors. The range gain is modest: roughly 0.13 kWh/100 km, or about 3 km on 400 km. The freed-up space may matter more to carmakers.

BYD, Xiaomi and GAC have also announced motors above 30,000 rpm, according to IDTechEx. ZF says it is talking to numerous carmakers but names none. Series production is planned by 2030, and the prototype has been on the test bench since February 2026.

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Tags:zfhigh revolution driveelectric driveev powertrainrare earths

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