ZF starts production of Steer-by-Wire technology with NIO

ZF has commenced mass production of its steer-by-wire technology for a prominent Chinese electric car manufacturer. The steer-by-wire technology, originating from the UK, is set to be integrated into NIO's flagship electric vehicle, the ET9. ZF Technology Group is providing the steering wheel actuator for steering and steering feel, along with the redundant steering gear actuator and associated software.

The Smart Electric Executive Flagship model boasts a lack of mechanical connection between the steering wheel and the front wheels. This cutting-edge technology is already in series production with another major global car manufacturer, and customer orders for the steer-by-wire system have been secured in Europe.

ZF established its Chassis Solutions Division at the start of 2024, focusing on electronically controlled steering and braking systems, controlled damping systems, and the innovative cubiX software for software-defined vehicles.

• Steer-by-wire for the chassis of the future
• Project provides vehicle dual controls

ZF's steer-by-wire steering system features a mechatronic actuator between the wheels as the sole means of transmitting steering inputs. The absence of a mechanical connection between the steering wheel and steering gear is a notable advancement. Steering commands are relayed by a steering wheel actuator in the cockpit, equipped with a corresponding angle of rotation sensor.

An electric drive, known as the torque feedback unit, replicates the natural steering feel and feedback from the road. The ZF system adjusts the steering ratio individually to ensure optimal adaptation for various driving speeds or scenarios.

“We are providing customers with the steering of the future. By introducing our production-ready steer-by-wire steering system, we are ushering in the era of the software-defined vehicle. With a comprehensive range of innovative by-wire technologies, we are a highly sought-after supplier and a key proponent of forward-looking chassis technologies,” states Dr. Peter Holdmann, Member of the Board of Management at ZF and head of the Chassis Solutions Division.

“At NIO, we are dedicated to delivering groundbreaking innovations that redefine the premium driving experience. Steer-by-wire technology serves as a crucial facilitator of software-defined vehicles, offering enhanced driving comfort, uncompromised dynamics, and future-proof technology,” remarks Danilo Teobaldi, Principal Chief Engineer at NIO.

“Our partnership with ZF, a globally recognized leader in high-quality automotive solutions, underscores our commitment to establishing new industry standards by deploying our smart EVs on a global stage.

“From the strategic alliance we forged with ZF in 2022 to the industrialization of this technology, we have demonstrated our capability to execute and deliver cutting-edge solutions. Together with ZF, we are shaping the future of intelligent and electrified mobility, setting new benchmarks for the industry.”

Combined with ZF's AKC mechatronic rear-wheel steering, this significantly enhances driving comfort in electric vehicles with an extended wheelbase. As a direct outcome of this new division, ZF announced a substantial order for brake-by-wire braking systems at the beginning of the year, totaling 5 million units for a leading global vehicle manufacturer.