Andreas Moser
As cities swell and air quality deteriorates, the case for zero-emission zones and electric mobility becomes essential—not just for cars, but also for construction sites, industrial yards, and agricultural fields. Global Technology company ZF is responding with climate-neutral E-Mobility Solutions tailored to diverse off-highway applications, from forklifts and compact excavators to electric tractors.
Electrification in industrial machinery is no longer a distant prospect. “It will come—it’s only a matter of speed,” Andreas Moser, Executive Vice President, ZF Industrial Technology, told Mobility Outlook. Drawing from his experience witnessing China’s rapid shift from diesel to electric buses, he believes similar transformations are underway across segments. In passenger cars, China already sets global benchmarks—and similar trends are expected in trucks, construction machinery, and agricultural vehicles.
Yet electrifying these segments isn’t straightforward. Equipment like 300-horsepower tractors could require batteries weighing up to five tonne—pushing the limits of current energy density and efficiency. Manufacturers must strike a delicate balance between cost, weight, and performance, especially in duty cycles where compact design and runtime matter.
In a segment where volumes are far smaller than passenger vehicles, sourcing reliable, high-voltage components like e-motors, inverters, and thermal systems presents its own challenge. Here, ZF’s scale is a strategic advantage. “We leverage e-machines from our passenger car business, adapted for industrial and commercial needs,” Moser mentioned. This integration enables consistent performance while maintaining supply reliability.
But not all needs can be met in-house. For niche or small-scale applications, ZF must turn to external suppliers—where securing consistent component quality in limited volumes remains a hurdle, he observed. While battery technology continues to evolve, Moser believes a mix of solutions—such as hydrogen ICE and flex-fuel powertrains—will coexist. The true challenge, he noted, lies in fragmentation; too many technologies across too few units risk undermining scale and delaying adoption.
Smarter Drivetrains, Connected Machines
As OEMs push for connected systems that enable predictive maintenance, fleet optimisation, and remote diagnostics, the company is leveraging its drivetrain intelligence to add deeper value to every machine. Embedded with advanced ECUs and integrated sensors, its systems not only power machines—they generate critical operational insights in real time.
“Our intelligent drivetrains link directly to the machine’s central computer, enabling data-rich applications that support smarter, more efficient equipment,” he explained. While OEMs often seek to retain ownership of this data, ZF uses it to refine its own components, learning directly from real-world use to improve design, performance, and durability.
The impact extends beyond construction and agriculture. For instance, in wind power, the company’s digital solutions track wear in large gearboxes to enable predictive maintenance—critical for ensuring uptime and reducing costly failures. Meanwhile, innovative tools like ‘Rescue Connect’ improve emergency response by digitally integrating people, tools, and assets across rail systems. The system connects data from rescue services like fire departments, ambulance or other emergency organizations to support emergency management and decision-makers not only in dealing with everyday tasks, but also in the event of large-scale and mass-casualty incidents. By analysing drivetrain data, ZF can also anticipate maintenance needs on connected railways, optimising both safety and service.
Modular Thinking, Scalable Tech
According to Moser, more than technical expertise, navigating the fragmented and cost-sensitive off-road vehicle market demands calls for strategic leverage, modular design, and cross-division collaboration. With customers ranging from global OEMs to niche players, the company balances high expectations for innovation with complex realities of low volumes, long product life cycles, and customisation demands.
A key advantage lies in the company’s ability to transfer advanced technologies from its high-volume automotive divisions. “Our industrial segment alone couldn’t justify the R&D cost of developing supercomputers for control logic,” admitted Moser. “But we can tap into high-performance computing platforms, like ZF’s Pro AI, originally designed for passenger cars.” These systems form the digital backbone for edge computing, cloud integration, and connected components—critical in remote, connectivity-challenged environments like construction sites or agricultural fields.
Still, adapting technologies from cars to off-highway equipment isn't always seamless. Different applications demand different tolerances, environmental resistance, and mechanical layouts. The Tier-1 company meets these challenges by maintaining tight integration with central R&D teams and tailoring solutions where needed—without compromising scale benefits, he said.
On the drivetrain side, innovation continues through steady evolution. Power shift transmissions are giving way to continuously variable transmissions (CVTs), offering greater efficiency and smoother operation. In electrification too, the company’s off-road strategy is more pragmatic than radical - pairing electric motors with simplified axles or transmissions within existing installation frames. Unlike in passenger vehicles, where in-house OEM competition is intense, off-road electrification offers a more open playing field—though scale limitations remain a constant hurdle.
According to him, modularity is central to ZF’s strategy for managing product variation. 'Even with long-life products expected to last 20–30 years, and with small batch orders, we can address customisation by tweaking housing interfaces or connection points,” he said. This approach reduces cost and complexity without sacrificing adaptability. For more significant changes, it often collaborates with OEMs to share development costs—though not always entirely, especially when exclusivity risks limiting wider application.
And when it comes to long-term investment, timing is everything. “You have to start early,” he emphasised. By initiating development work well in advance, the company spreads engineering costs over time—ensuring both technological readiness and financial sustainability.
From Bench To Breakthrough
What began decades ago as an in-house need to test ZF’s own transmissions and axles, has evolved into a globally competitive business under ZF’s Industrial Technology division. Today, ZF Test Systems has transformed into a cutting-edge solutions provider, with 75% of its business now coming from external customers.
The shift from conventional to electric drivetrains has redefined its test systems portfolio. A majority of recent business has centred around advanced test benches for high-volume battery production. Every battery module—and in some cases, each individual cell—is thoroughly tested, not just for pass/fail criteria, but for deep diagnostic data. “We’re talking about up to 300 MB of data per test object,” he noted adding that this vast data stream supports smarter quality control and enables AI-driven analytics.
But as electric drivetrains become quieter and cleaner, attention has turned to another major pollutant - brake dust. As part of broader Euro-7 regulatory shifts, ZF has pioneered test equipment to measure and analyse brake particle emissions. The Brake Emission Tester, recently showcased by ZF, is the result of years of R&D and is already being used by OEMs like BMW and leading tyre manufacturers, he mentioned.
This new generation of test systems doesn’t just collect emissions data—it applies AI to uncover patterns and predictive insights, offering a unique solution that blends precision hardware with intelligent software.
For ZF, the strategy is clear—stay flexible, draw from group synergies, and prepare for a diverse electric future that will inevitably reach even the most rugged machines. Moser concluded stating that ultimately, ZF’s playbook for the off-highway segment hinges on flexible platforms, early innovation, and the unique ability to scale automotive-grade technologies into rugged, real-world machines.
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