Introduction:
ZF commercial vehicle control systems is the Indian subsidiary of the ZF Global. The company primarily is in the auto ancillaries’ space for commercial vehicles. Previously known as Wabco India Limited, the company is a leading supplier of technologies and services that improve the safety, efficiency, and connectivity of commercial vehicles in India.
The company excels in pioneering breakthrough innovations that bring industry-leading solutions to the commercial vehicle industry in India and worldwide. The company is a world-class manufacturer and local market leader in advanced braking systems, conventional braking products and related air assisted technologies and systems.
With five world-class manufacturing facilities spread across India, Application Engineering Centre in Pune, technology center and a vehicle testing facility in Chennai, WABCO INDIA excels in engineering and manufacturing, serving customers locally and through WABCO internationally.
It was formed as a joint venture between TVS Group and WABCO Holdings Inc. The company has pioneered the manufacture of air-assisted and air brake systems for commercial vehicles in India. With a commitment of total satisfaction to customers, their company has achieved a share of business in the OE (Original Equipment) segment greater than 85% and a market share in the after-market greater than 75%.
WABCO-TVS has a solid foundation in its domestic market leadership and pioneering R&D efforts. Comprehensive TQM (Total Quality Management) practices enables WABCO-TVS in being a competitive world-class manufacturer in terms of quality, cost and timely delivery of products.
With intensive R&D efforts and high quality standards, its products have found global acceptance. Today Australia, Malaysia, UK, Singapore, South Asia, North America, Venezuela and the Middle East are part of its export network.
Product:
The company is the leading provider for air brake actuation systems for commercial vehicles. Its key products include:
Automatic Slack Adjusters
Actuators
Brake Chambers
Valves
Drying and Distribution Unit
Air Compressors
Advanced Braking Systems
Air Suspension
Clientele:
The company supplies original equipment fitments for vehicles manufactured by Ashok Leyland, TATA Motors, Vehicle Factory (Jabalpur), Bharat Earthmovers, TAFE, Volvo, SUTLEJ, CATERPILLAR, Eicher Motors, Swaraj Mazda, Force Motors, Mahindra & Mahindra, Tata Cummins (Engines) and a host of other trailer manufacturers.
Detailed Product Portfolio
Below is the list of products for the company across various segments:
- Car Products:
| Product | Description |
| Continuous Damping control | Continuous Damping Control available as CDCivo and CDCevo solves the conflict between driving safety and ride comfort by setting the damper – and uncompromisingly. Whether fully loaded or only with the driver, the CDC®-system adjusts the optimum damping wheel-individually according to the driving situation. |
| Short Range Radar | The corner radar provides the required data for the lane assistant, blind spot assistant, and lane change assistant. It records its surroundings in a range of up to 90 meters in a grid of 20 cylinders and an angle of +/- 75 degrees. Thanks to its 77 GHz RFCMOS technology, it is suitable for automated driving functions. |
| E beam axle | Electric beam axle including e-motor, inverter, transmission and axle structure up to the brakes. A flexible architecture for 400 Volt and 800 Volt solutions including integrated inverters featuring SiC-based power modules. Various options such as differential locking devices, park-lock or rear-axle steering. Highly integrated for easy vehicle assembly and future-proof through ZF’s broad electric portfolio. |
- Buses Products:
| Type | Product |
| Active Safety | Air valves for brake control |
| Active Safety | Anti lock braking systems |
| Active Safety | Automatic slack adjusters |
| Active Safety | Electric powered hydraulic steering pump |
| Active Safety | Electronic braking system |
| Active Safety | L4 ReAX – autonomous driving system / braking system/ steering and gear systems |
| Active Safety | PAN Air disc Brake |
| Active Safety | Anticipatory camera system |
| Active Safety | Modular Braking system platform |
| Chassis | AV 110 Portal Axle for midi buses |
| Chassis | Air Suspension Solutions – Electronic controlled air suspension systems, Electronic shock absorber control |
| Chassis | Axle Dampers |
| Chassis | Axle Systems |
| Chassis | Tie Rod |
| Chassis | V Links |
| Compressed air management | Electronic Air Processing Units |
| Compressed air management | Engine driven compressors |
| Compressed air management | Mechanical air processing units |
| Compressed air management | e-comp |
| Digital solutions | Bach Onboard device |
| Digital solutions | Driver Feedback Device |
| Digital solutions | OpenMatics Portal |
| Digital solutions | Roadcaster Unit |
| Digital solutions | VCU Pro Onboarder Unit |
| Driveline | AS Tronic |
| Electronics | Radar Systems |
| Electronics | ESC Smart |
| Electronics | EST |
| Electronics | Inverter |
| Electronics | Modular Door control system |
| Electronics | On Guard Assist |
| Electronics | On Lane alert |
| Electronics | Opti Tire |
| Electronics | Short range radar |
| Electronics | Tail Guard |
| Passive Safety | HOD Steering wheel for commercial vehicles |
Below is the detailed description for the above products:
| Product | Description |
| Air Valves for Brake control | ZF offers a broad range of brake control valves which build the foundation for safe vehicle operations while supporting the commercial vehicle‘s braking system performance. Amongst others, this product range includes hand brake valves, foot brake valves, 3/2 solenoids valves. |
| Anti lock braking systems | These active safety systems assist drivers in situations where combinations of road friction, road curvature and vehicle speed result in an unfavorable wheel slip. The systems automatically intervene to help keep the vehicle stable and controllable in a wide range of different maneuvers. |
| Automatic slack adjusters | ZF’s proven Automatic Slack Adjuster helps to achieve higher safety and efficiency levels. It constantly ensures the adjustment of running clearance, even under extreme temperature conditions, and reliably transmits the correct power from the brake chamber to the drum brake. |
| Electric powered hydraulic steering pump | ZF’s EPHS Electrically Powered Hydraulic Steering Pump allows flexibility in vehicle design. EPHS can be used within current vehicle architecture to provide hydraulic power steering in vehicles with hybrid and engine off operations or full electric powertrains. |
| Electronic braking system | This advanced brake control technology transfers the driver’s deceleration request electronically to all braking system components to shorten response time, balance brake forces and provide efficient brake management between service and endurance brakes. With exceptional brake performance this market-leading Electronic Braking System (EBS) provides the full range of brake control functions for tough commercial vehicle applications. |
| L4 ReAX – autonomous driving system / braking system/ steering and gear systems | ZF’s L4 ReAX the road to autonomous driving being paved by advanced sensors combined with fail operational vehicle control systems and a powerful computing platform. L4 ReAX steering technology utilizes market leading automotive electric steering technology in redundant circuit configuration to meet the standards required for steering automation of autonomous vehicles. ZF’s ReAX adaptive steering technology utilizes market leading automotive electric steering technology to optimize steering performance in commercial vehicles. This system adapts to signals from the vehicle and analyzes driver input to provide smoother, more precise steering, helping to improve performance and reduce driver fatigue. |
| PAN Air disc Brake | The PAN range of air disc brakes has a long and successful history in the commercial vehicles sector. The compact design, developed using leading-edge finite element analysis, uses proven single-piston technology to achieve class-leading weight reduction targets. Reliability is supported by an encapsulated guiding system with stable metal caps as well as redundant sealing systems with pin guidance and an adjuster device. |
| Anticipatory camera system | The S-Cam4T is a front camera for truck applications and features two lenses (52 degrees and 150 degrees), allowing it to cover both long-distance and close-up ranges. The central image processing module (IPM) ensures the most advanced object recognition and classification – for example, that of traffic signs. The S-Cam4T is suitable for sensor fusion in combination with other systems. |
| Modular Braking system platform | ZF’s mBSP features a high degree of software standardization across its ABS and EBS systems. It also reduces the number of ABS components to the same amount as an EBS. By leveraging the advantages of mBSP, vehicle manufacturers can significantly reduce system development, installation and software testing time for their diverse brands and vehicle portfolios globally, and bring new trucks and buses to market faster. |
| AV 110 Portal Axle for midi buses | Midibuses (19.5 inch) and the modular AV 110 rear axle model range, purpose-built by ZF, have many things in common – like compact dimensions and low weight. With the portal axle, low-floor concepts can now also be realized in the midibus. |
| Air Suspension Solutions – Electronic controlled air suspension systems, Electronic shock absorber control | ZF’s suspension control solutions help to increase passenger and driver safety, enhancing vehicle stability through mitigation of excessive pitching and rolling, while also improving comfort through better ride quality and effortless entry and exit. A broad variety of value-adding functionalities enable fleets to bring their daily operations to a whole new level. |
| Axle Dampers | The primary suspension absorbs excitations originating from the road. The suspension enables the wheel to follow the unevenness of the road. However, the stored energy is released again by the suspension system when the wheel is rebounding. The chassis needs shock absorbers to dampen vibrations caused by this as quickly as possible.Sprung and unsprung masses vibrate in different frequency ranges. Shock absorbers aligned with vehicle suspension basically prevent the body from rocking and vibrating. They ensure permanent road grip of the wheels and thus good lateral guidance and braking effects. Damping plays a decisive role in driving safety and ride comfort. |
| Axle Systems | Besides the active steering model, the passive steering version of the RL 75 A is also available as a tag axle for longer buses. It is fitted with steering dampers and pneumatic locking cylinders. As an alternative, the RL 82 EC independent front suspension can also be used as a tag axle. The wheel heads on the tag axles are identical to the wheel heads on both front axles. In addition, chassis integration is easy as both front axles have identical installation dimensions. |
| Tie Rod | When it comes to our proven ZF joint design or our fine-tuning system for tie rods and drag links, we set the benchmark. We stand for zero maintenance, low weight, and space-saving design. Also high on our list of priorities are reliability and long service life. The successful product sets new standards with its low weight and space-saving dimensions, and impresses with improved wheel guidance behavior and reduced noise. Meanwhile, well over 15 million joints have already left the shop floor |
| V Links | Links are used primarily with heavily loaded rear axles, for instance in semi-trailer tractors or flatbed vehicles with twin axle assemblies. Our optimization has resulted in V-links with reduced weight. Here intelligent lightweight construction and functional optimization are achieved in conjunction with cost savings and improved vehicle dynamics. During optimization, top priority is always assigned to the safety aspects of the chassis. |
| Electronic Air Processing Units | Air processing solutions dry, clean, store and distribute the compressed air to enable proper system operation under all conditions. Electronic Air Processing Units (E-APUs) and Electronically Controlled Air Processing Units (EC-APUs) deliver extra fuel savings thanks to intelligent air compressor control. |
| Engine driven compressors | Compressors generate the pressurized air used in the braking system, air suspension and other air-based applications. ZF compressors feature highly sophisticated components like high-efficiency die-cast aluminum cylinder heads, power reduction systems and water jackets. Customers can select from a wide range of road-proven options, either as a single option or as a combined package. |
| Mechanical air processing units | New generation of mechanical air processing technology combining an innovative quad-valve with proven air dryer and air cartridge systems in superbly engineered designs. Mechanical air processing units dry, clean, store and distribute the compressed air to enable proper system operation under all conditions. |
| e-comp | e-comp provides an efficient and robust solution that can work off an independent power source for vehicles with hybrid and full electric drivelines. The modular design enables customization for all types of vehicles. Its electric motor facilitates fast and simple installation independent from the vehicle’s engine. |
| Bach Onboard device | The compact Bach Onboard Unit serves as the central link between the vehicle and the ZF OPENMATICS telematics portal: Developed for use in buses and trucks, the unit makes fleet and order management as well as asset tracking easier for fleet operators. The device reads, records and transmits freight and vehicle information to the cloud. The Bach Onboard Unit is compatible with most vehicle brands and thus the perfect solution for mixed fleets. |
| Driver Feedback Device | Eco-friendly driving contributes to reducing costs for fuel and maintenance. Our Driver Feedback Device is a smart addition to the ZF OPENMATICS telematics system: An LED and audio signal alerts drivers as soon as they exceed a limit value. Analyze the driving behavior of your drivers and receive reports on inadmissible driving behavior. |
| OpenMatics Portal | The OPENMATICS Portal 2.0 brings next generation telematics to your fleet: Our cloud-based tool provides you with clear evaluations of all relevant data structured to suit your requirements – in real time. This gives fleet managers a complete overview of the current order situation, trips, vehicle conditions and maintenance plans at all times. The OPENMATICS Portal 2.0 is compatible with the tried-and-tested Bach Onboard Unit as well as with the advanced VCU Pro Onboard Unit. |
| Roadcaster Unit | Traveling is much more fun when you can enjoy high-quality entertainment on the way. With the Roadcaster Unit, the wireless onboard infotainment system for city buses and coaches, passengers can enjoy films, series and music or surf the Internet via a stable, on-board WiFi hot spot. ZF OPENMATICS offers the Roadcaster Unit as an extensive all-in-one solution in a package including user interface, overview portal and media licenses. |
| VCU Pro Onboarder Unit | With the VCU Pro Onboard Unit, ZF is offering fleet operators a new generation of progressive and robust telematics hardware. The unit features four CAN interfaces as well as a dual processor and supports WiFi and Bluetooth 4.2 as well as all popular GNSS. Secure OTA updates ensure that the software is always up-to-date. Combined with the OPENMATICS Portal 2.0 , the VCU Pro Onboard Unit allows you to tailor your fleet management to your individual needs. |
| Radar Systems | The AC1000T is a 77 GHz mid-range radar system. It features more precise speed resolution and an expanded range of up to 200 meters. Thanks to a horizontal opening angle of up to 70 degrees, systems such as adaptive cruise control, anticipatory collision warning and automatic emergency braking are enhanced to offer advanced safety and semi-automated comfort functions are also enabled. |
| ESC Smart | This Electronic Stability Control system supports the truck or bus driver to keep the commercial vehicle stable especially in dynamic driving maneuvers. The system automatically intervenes where vehicle stability enters a critical phase. By this means ESCsmart helps to protect the vehicle against rollover, skidding and – in case of a truck-trailer combination – jackknifing. |
| EST | The electronic EST 54 control unit, which has already proven its value in EcoLife transmissions, uses the SAE-J-1939 standard to communicate with drive and vehicle components and also features a diagnostic interface. The software can be adapted to the specific vehicle and telematics solutions offer a variety of additional features. |
| Inverter | The high voltage inverters used by ZF dispose of a nominal voltage of from 350 to 650 volts. They control the asynchronous motors of the ZF drives and are optimized on the electric drive system. |
| Modular Door control system | Our Modular Door Control systems offer safety features for different bus variants. Its modular structure controls up to 8 doors offering universal use and quick adaptation to different bus variants. Our Door Control Systems can both control pneumatically and electrically driven doors. |
| On Guard Assist | dvanced Emergency Braking System (AEBS) helps avoid or mitigate rear-end collisions with vehicles ahead. This active safety system assists drivers in recognizing and responding to dangerous driving situations that could lead to a rear-end collision with a moving, stopping or stationary vehicle ahead. |
| On Lane alert | This Lane Departure Warning System is specifically designed for commercial vehicles. Leveraging a forward-looking windshield-mounted camera, the system monitors the vehicle’s position within the lane. When the system detects the vehicle crossing lane markings without a turn signal being activated, the system alerts the driver to take corrective action. By this means, OnLaneALERT can effectively help to prevent road run-offs, side swipes, and head-on collisions. |
| Opti Tire | This tire pressure monitoring system is specifically designed for commercial vehicle. The system offers internal and external wheel sensors, including simple to install strap-mounted sensors, covering all rim sizes and applications. This system constantly monitors the performance of each tire. As soon as a tire issue is detected, OptiTire alerts the driver to help optimize vehicle uptime, tire life and fuel efficiency – making journeys safer and more economical. |
| Short range radar | The corner radar provides the required data for the lane assistant, blind spot assistant, and lane change assistant. It records its surroundings in a range of up to 90 meters in a grid of 20 cylinders and an angle of +/- 75 degrees. Thanks to its 77 GHz RFCMOS technology, it is suitable for automated driving functions. |
| Tail Guard | This active safety technology is the commercial vehicle industry’s first Reversing Collision Avoidance System. The system is designed to detect static and moving objects in the blind spot behind the vehicle. With warning and active braking, the system assists the driver during reversing maneuvers. Aiming for avoiding any impending collision, TailGUARD can automatically bring the vehicle to a complete stop.By this means, this technology can effectively help to maximize safety and vehicle uptime. |
| Vehicle electronic systems | The Vehicle Control Module (VCM) is a central electronic control unit managing the dynamic longitudinal control of a commercial vehicle. It coordinates the powertrain, including engine, transmission and retarder, while also integrating ADAS functions such as Adaptive Cruise Control or Predictive Economic Cruise Control. The Central Vehicle Controller (CVC/MUX) manages the electrical loads throughout the vehicle to orchestrate vehicle functions such as light, wiper or climate control. |
| HOD Steering wheel for commercial vehicles | ZF’s steering wheel with Hands On Detection (HOD), ECU and software is available in different variants and styles, comprising a capacitive system that is designed to detect the driver’s availability and condition and act as Human Machine Interface (HMI). The Hands On Detection steering wheel is equipped with Rim Heating |
- Trailer Products:
| Type | Product |
| Active Safety | Automatic Slack Adjusters |
| Active Safety | PAN Air Disc Brake |
| Active Safety | Anti lock braking systems |
| Active Safety | Electronic braking system |
| Chassis | Axle Dampers |
| Chassis | Air Suspension Solutions – Electronic controlled air suspension systems, Electronic shock absorber control |
| Chassis | Optilevel |
| Chassis | Trailer lift axle control |
| Electronics | OptiTire |
| Electronics | TailGuard |
| Intelligent trailer program | ITP Advanced Safety |
| Intelligent trailer program | ITP Driver effectiveness |
| Intelligent trailer program | ITP Program Fuel and CO2 reduction |
| Intelligent trailer program | ITP Load Optimisation |
Below is the detailed description for the above products:
| Product | Description |
| Automatic Slack Adjusters | ZF’s proven Automatic Slack Adjuster helps to achieve higher safety and efficiency levels. It constantly ensures the adjustment of running clearance, even under extreme temperature conditions, and reliably transmits the correct power from the brake chamber to the drum brake. |
| PAN Air Disc Brake | The PAN range of air disc brakes has a long and successful history in the commercial vehicles sector. The compact design, developed using leading-edge finite element analysis, uses proven single-piston technology to achieve class-leading weight reduction targets. Reliability is supported by an encapsulated guiding system with stable metal caps as well as redundant sealing systems with pin guidance and an adjuster device. |
| Anti lock braking systems | These active safety systems assist drivers in situations where combinations of road friction, road curvature and vehicle speed result in an unfavorable wheel slip. The systems automatically intervene to help keep the vehicle stable and controllable in a wide range of different maneuvers. |
| Electronic braking system | This advanced brake control technology transfers the driver’s deceleration request electronically to all braking system components to shorten response time, balance brake forces and provide efficient brake management between service and endurance brakes. With exceptional brake performance this market-leading Electronic Braking System (EBS) provides the full range of brake control functions for tough commercial vehicle applications. |
| Axle Dampers | The primary suspension absorbs excitations originating from the road. The suspension enables the wheel to follow the unevenness of the road. However, the stored energy is released again by the suspension system when the wheel is rebounding. The chassis needs shock absorbers to dampen vibrations caused by this as quickly as possible.Sprung and unsprung masses vibrate in different frequency ranges. Shock absorbers aligned with vehicle suspension basically prevent the body from rocking and vibrating. They ensure permanent road grip of the wheels and thus good lateral guidance and braking effects. Damping plays a decisive role in driving safety and ride comfort. |
| Air Suspension Solutions – Electronic controlled air suspension systems, Electronic shock absorber control | ZF’s suspension control solutions help to increase passenger and driver safety, enhancing vehicle stability through mitigation of excessive pitching and rolling, while also improving comfort through better ride quality and effortless entry and exit. A broad variety of value-adding functionalities enable fleets to bring their daily operations to a whole new level. |
| Opti Level | ZF’s OptiLevel offers a more economical control of trailer height than conventional air suspension methods. The system brings together six valuable trailer suspension functions in a single, economic package. OptiLevel helps to cut fuel costs, decrease loading and unloading times, reduce the risk of accidents and allow docked trailers to change height level without an attached tractor – Trailer air suspension at its best. |
| Trailer lift axle control | The system provides lift and tag axle control through a multitude of value-adding functions to optimize operating times, improve fuel efficiency, decrease tire wear, and lower CO2 emissions. Lift Axle Control automatically lifts or lowers the lift axle if load conditions allow it, thus reducing tire wear and rolling resistance. It also helps to prevent damage by intelligently charging or uncharging tag axles. |
| Opti Tire | This tire pressure monitoring system is specifically designed for commercial vehicle. The system offers internal and external wheel sensors, including simple to install strap-mounted sensors, covering all rim sizes and applications. This system constantly monitors the performance of each tire. As soon as a tire issue is detected, OptiTire alerts the driver to help optimize vehicle uptime, tire life and fuel efficiency – making journeys safer and more economical. |
| Tail Guard | This active safety technology is the commercial vehicle industry’s first Reversing Collision Avoidance System. The system is designed to detect static and moving objects in the blind spot behind the vehicle. With warning and active braking, the system assists the driver during reversing maneuvers. Aiming for avoiding any impending collision, TailGUARD can automatically bring the vehicle to a complete stop.By this means, this technology can effectively help to maximize safety and vehicle uptime. |
| ITP Advanced Safety | The Intelligent Trailer Program safety features make delicate trailer driving situations such as cornering, braking, reversing or delivering safer and easier for the driver. This suite of trailer functions helps to reduce damages as well as repair costs and increases uptime. |
| ITP Driver effectiveness | Retaining skilled drivers is the key to run an efficient operation, which is why the trailers should help supporting their daily routines. These Intelligent Trailer Program functions provide a toolbox to contribute to effectiveness, safety and comfort, designed to make trailer operations easier and more effective for the driver. |
| ITP Program Fuel and CO2 reduction | These Intelligent Trailer Program functions aim to maximize fuel savings via automation, designed to work with minimum driver intervention. The functions allow the trailer to provide significant fuel and CO2 emission savings of the combined commercial vehicle, helping fleet and cargo owners to meet CO2 emission reduction goals. |
| ITP Load Optimisation | The weight and distribution of cargo on the trailer has implications for safety, driver comfort, fuel efficiency and maintenance. This suite of trailer functions helps to prevent trailer overload and also to optimize cargo distribution and vehicle stability throughout the journey for the best possible performance. |
| ITP Operational effeciency | The Intelligent Trailer Program operational efficiency features provide more knowledge on the vehicle for both driver and fleet management. These customizable smart functions are designed to enhance efficiency by accelerating and/or simplifying trailer operations while providing key indicators on its status. |
- LCV Products
| Type | Product |
| Active Safety | Full electric steering gear |
| Active Safety | Anticipatory Camera System |
| Chassis | Continuous Damping control |
| Electronics | Radar System for speed assistance |
| Electronics | Short range radar system |
Below is the detailed description for the above products:
| Product | Description |
| Full electric steering gear | ReAX-e provides fully electric steering actuation for light duty commercial vehicles. It is designed to fit in conventional vehicle steering architecture replacing the hydraulic power steering system. ReAX-e is ideal for hybrid electric and fully electric vehicles, it also provides fuel savings in internal combustion vehicles. It also enables ADAS, automated driving, and remote steering capabilities. |
| Anticipatory Camera System | The S-Cam4T is a front camera for truck applications and features two lenses (52 degrees and 150 degrees), allowing it to cover both long-distance and close-up ranges. The central image processing module (IPM) ensures the most advanced object recognition and classification – for example, that of traffic signs. The S-Cam4T is suitable for sensor fusion in combination with other systems. |
| Continuous Damping control | Continuous Damping Control available as CDCivo and CDCevo solves the conflict between driving safety and ride comfort by setting the damper – and uncompromisingly. Whether fully loaded or only with the driver, the CDC®-system adjusts the optimum damping wheel-individually according to the driving situation. |
| Radar Systems | The AC1000T is a 77 GHz mid-range radar system. It features more precise speed resolution and an expanded range of up to 200 meters. Thanks to a horizontal opening angle of up to 70 degrees, systems such as adaptive cruise control, anticipatory collision warning and automatic emergency braking are enhanced to offer advanced safety and semi-automated comfort functions are also enabled. |
| Short range radar | The corner radar provides the required data for the lane assistant, blind spot assistant, and lane change assistant. It records its surroundings in a range of up to 90 meters in a grid of 20 cylinders and an angle of +/- 75 degrees. Thanks to its 77 GHz RFCMOS technology, it is suitable for automated driving functions. |
- Trucks Products
| Type | Product |
| Active Safety | Air valves for brake control |
| Active Safety | Anti lock braking systems |
| Active Safety | Automatic slack adjusters |
| Active Safety | Electric powered hydraulic steering pump |
| Active Safety | Electronic braking system |
| Active Safety | L4 ReAX – autonomous driving system / braking system/ steering and gear systems |
| Active Safety | PAN Air disc Brake |
| Active Safety | Anticipatory camera system |
| Active Safety | Modular Braking system platform |
| Active Safety | PAN Air disc brakes |
| Active Safety | Advanced anticipatory Camera |
| Active Safety | Standardisation between ABS and EBS systems |
| Active Safety | Brake Chambers |
| Chassis products | Air Suspension Solutions – Electronic controlled air suspension systems, Electronic shock absorber control |
| Chassis products | Axle Dampers |
| Chassis products | Axle Systems |
| Chassis products | Tie Rod |
| Chassis products | V Links |
| Chassis products | 4-point Link |
| Chassis products | AirTrac |
| Chassis products | Active Cabin Suspension System |
| Chassis products | Cabin Suspension with Anti Roll bar |
| Chassis products | Continuous damping control |
| Chassis products | Electronic cabin air levelling system |
| Chassis products | Planetary Steering Axle |
| Chassis products | Suspension Rear twin axle |
| Compressed air management | Electronic Air management systems |
| Compressed air management | Engine driven compressors |
| Compressed air management | Mechanical air processing units |
| Compressed air management | Independent power source for hybrid and full electric vehicles |
| Electronics | Radar Systems |
| Electronics | ESC Smart |
| Electronics | EST |
| Electronics | Inverter |
| Electronics | On Guard Assist |
| Electronics | On Lane alert |
| Electronics | Opti Tire |
| Electronics | Short range radar |
| Electronics | Tail Guard |
| Electronics | Vehicle electronic systems |
| Passive safety | HOD Steering wheel for commercial vehicles |
Below is the detailed description for the above products:
| Product | Description |
| Air valves for brake control | ZF offers a broad range of brake control valves which build the foundation for safe vehicle operations while supporting the commercial vehicle‘s braking system performance. Amongst others, this product range includes hand brake valves, foot brake valves, 3/2 solenoids valves. |
| Anti lock braking systems | These active safety systems assist drivers in situations where combinations of road friction, road curvature and vehicle speed result in an unfavorable wheel slip. The systems automatically intervene to help keep the vehicle stable and controllable in a wide range of different maneuvers. |
| Automatic slack adjusters | ZF’s proven Automatic Slack Adjuster helps to achieve higher safety and efficiency levels. It constantly ensures the adjustment of running clearance, even under extreme temperature conditions, and reliably transmits the correct power from the brake chamber to the drum brake. |
| Electric powered hydraulic steering pump | ZF’s EPHS Electrically Powered Hydraulic Steering Pump allows flexibility in vehicle design. EPHS can be used within current vehicle architecture to provide hydraulic power steering in vehicles with hybrid and engine off operations or full electric powertrains. |
| Electronic braking system | This advanced brake control technology transfers the driver’s deceleration request electronically to all braking system components to shorten response time, balance brake forces and provide efficient brake management between service and endurance brakes. With exceptional brake performance this market-leading Electronic Braking System (EBS) provides the full range of brake control functions for tough commercial vehicle applications. |
| L4 ReAX – autonomous driving system / braking system/ steering and gear systems | ZF’s L4 ReAX the road to autonomous driving being paved by advanced sensors combined with fail operational vehicle control systems and a powerful computing platform. L4 ReAX steering technology utilizes market leading automotive electric steering technology in redundant circuit configuration to meet the standards required for steering automation of autonomous vehicles. ZF’s ReAX adaptive steering technology utilizes market leading automotive electric steering technology to optimize steering performance in commercial vehicles. This system adapts to signals from the vehicle and analyzes driver input to provide smoother, more precise steering, helping to improve performance and reduce driver fatigue. |
| PAN Air disc Brake | The PAN range of air disc brakes has a long and successful history in the commercial vehicles sector. The compact design, developed using leading-edge finite element analysis, uses proven single-piston technology to achieve class-leading weight reduction targets. Reliability is supported by an encapsulated guiding system with stable metal caps as well as redundant sealing systems with pin guidance and an adjuster device. |
| Anticipatory camera system | The S-Cam4T is a front camera for truck applications and features two lenses (52 degrees and 150 degrees), allowing it to cover both long-distance and close-up ranges. The central image processing module (IPM) ensures the most advanced object recognition and classification – for example, that of traffic signs. The S-Cam4T is suitable for sensor fusion in combination with other systems. |
| Modular Braking system platform | ZF’s mBSP features a high degree of software standardization across its ABS and EBS systems. It also reduces the number of ABS components to the same amount as an EBS. By leveraging the advantages of mBSP, vehicle manufacturers can significantly reduce system development, installation and software testing time for their diverse brands and vehicle portfolios globally, and bring new trucks and buses to market faster. |
| Brake Chambers | Trusted brake chamber technology available in multiple variants comprising service brake chambers, piston type and double diaphragm spring brake chambers. ZF‘s brake chambers ensure the correct transmission of pressure to the brake. While UNISTOP reliably actuates the service brake, TRISTOP and TRISTOP D also enable parking and fail-safe braking functions. |
| Air Suspension Solutions – Electronic controlled air suspension systems, Electronic shock absorber control | ZF’s suspension control solutions help to increase passenger and driver safety, enhancing vehicle stability through mitigation of excessive pitching and rolling, while also improving comfort through better ride quality and effortless entry and exit. A broad variety of value-adding functionalities enable fleets to bring their daily operations to a whole new level. |
| Axle Dampers | The primary suspension absorbs excitations originating from the road. The suspension enables the wheel to follow the unevenness of the road. However, the stored energy is released again by the suspension system when the wheel is rebounding. The chassis needs shock absorbers to dampen vibrations caused by this as quickly as possible.Sprung and unsprung masses vibrate in different frequency ranges. Shock absorbers aligned with vehicle suspension basically prevent the body from rocking and vibrating. They ensure permanent road grip of the wheels and thus good lateral guidance and braking effects. Damping plays a decisive role in driving safety and ride comfort. |
| Axle Systems | Besides the active steering model, the passive steering version of the RL 75 A is also available as a tag axle for longer buses. It is fitted with steering dampers and pneumatic locking cylinders. As an alternative, the RL 82 EC independent front suspension can also be used as a tag axle. The wheel heads on the tag axles are identical to the wheel heads on both front axles. In addition, chassis integration is easy as both front axles have identical installation dimensions. |
| Tie Rod | When it comes to our proven ZF joint design or our fine-tuning system for tie rods and drag links, we set the benchmark. We stand for zero maintenance, low weight, and space-saving design. Also high on our list of priorities are reliability and long service life. The successful product sets new standards with its low weight and space-saving dimensions, and impresses with improved wheel guidance behavior and reduced noise. Meanwhile, well over 15 million joints have already left the shop floor |
| V Links | Links are used primarily with heavily loaded rear axles, for instance in semi-trailer tractors or flatbed vehicles with twin axle assemblies. Our optimization has resulted in V-links with reduced weight. Here intelligent lightweight construction and functional optimization are achieved in conjunction with cost savings and improved vehicle dynamics. During optimization, top priority is always assigned to the safety aspects of the chassis. |
| 4-point Link | The 4-point link integrates the functions previously performed separately by the V-link and the stabilizer bar, and fulfills all of the familiar roll stabilization requirements. Axle control is ensured even in extreme driving conditions, ground clearance is improved considerably in comparison to previously existing systems, and the weight of the system is reduced by an average of 20 kilograms. |
| AirTrac | The AIRTRAC suspension from ZF offers a comfortable and reliable overall solution for modern truck chassis. |
| Active Cabin Suspension System | The electronically controlled active cCAB system can actively move the cab, anticipating undesired movements and preemptively working against them. cCAB was systematically and further developed from the successful CDC and CALM systems and was expanded to include an electrohydraulic actuator. |
| Cabin Suspension with Anti Roll bar | Comfort and optimized use of space ZF develops cabin suspensions for various requirements. The result? Good working conditions for drivers. Just like the commercial vehicles themselves, the cabin suspensions are designed for very different applications. The requirements range from robust off-road capabilities, e.g. for construction vehicles or tractors, to comfort-optimized designs for longdistance driving on freeways. |
| Continuous damping control | CDC is a damping control system for commercial vehicles that combines uncompromising comfort and driving safety. With improved acoustics, reduced vibrations and controlled cab movements under the effects of shifting loads, it improves workplace ergonomics overall. Especially in electric driven buses with batteries on the roof it prevents dangerous dynamic pitching while combining vehicle stability with passenger comfort. |
| Electronic cabin air levelling system | The electronically controlled eCALM is the logical further development of the successful CALM. Because the best working conditions in the cab are becoming increasingly important. With eCALM, commercial vehicles can benefit from the comfort advantages of a pneumatically suspended cab – and from additional functions such as levelling, lowering, or raising the cab to different levels. The electronic control reduces air and energy consumption. |
| Planetary Steering Axle | The APL 90 axle has been specially designed for all-wheel drive trucks. Even on most adverse conditions, this axle ensures optimum traction characteristics. Due to the balanced steering kinematics, the vehicles are very easily maneuverable and thereby reduce wear and tear for the tires and road surface. An ABS-controlled drum brake which is particularly suitable for the demands of off-road use, completes this axle. |
| Suspension Rear twin axle | Innovative twin rear axle suspension: The GFC version of the 4-point link is part of a weight-optimized truck suspension system for the rear twin axle. The 4-point link is responsible for locating the non-driven leading axle with its weight-optimized hollow-cast design. The live rear axle features a stabilizer link with new polygon joining technology: Together with a lightweight aluminum v-link and a spring bellows carrier, it takes over both the axle guidance and the vertical axle load support |
| Electronic Air Processing Units | Air processing solutions dry, clean, store and distribute the compressed air to enable proper system operation under all conditions. Electronic Air Processing Units (E-APUs) and Electronically Controlled Air Processing Units (EC-APUs) deliver extra fuel savings thanks to intelligent air compressor control. |
| Engine driven compressors | Compressors generate the pressurized air used in the braking system, air suspension and other air-based applications. ZF compressors feature highly sophisticated components like high-efficiency die-cast aluminum cylinder heads, power reduction systems and water jackets. Customers can select from a wide range of road-proven options, either as a single option or as a combined package. |
| Mechanical air processing units | New generation of mechanical air processing technology combining an innovative quad-valve with proven air dryer and air cartridge systems in superbly engineered designs. Mechanical air processing units dry, clean, store and distribute the compressed air to enable proper system operation under all conditions. |
| e-comp | e-comp provides an efficient and robust solution that can work off an independent power source for vehicles with hybrid and full electric drivelines. The modular design enables customization for all types of vehicles. Its electric motor facilitates fast and simple installation independent from the vehicle’s engine. |
| HOD Steering wheel for commercial vehicles | ZF’s steering wheel with Hands On Detection (HOD), ECU and software is available in different variants and styles, comprising a capacitive system that is designed to detect the driver’s availability and condition and act as Human Machine Interface (HMI). The Hands On Detection steering wheel is equipped with Rim Heating |
| Radar Systems | The AC1000T is a 77 GHz mid-range radar system. It features more precise speed resolution and an expanded range of up to 200 meters. Thanks to a horizontal opening angle of up to 70 degrees, systems such as adaptive cruise control, anticipatory collision warning and automatic emergency braking are enhanced to offer advanced safety and semi-automated comfort functions are also enabled. |
| ESC Smart | This Electronic Stability Control system supports the truck or bus driver to keep the commercial vehicle stable especially in dynamic driving maneuvers. The system automatically intervenes where vehicle stability enters a critical phase. By this means ESCsmart helps to protect the vehicle against rollover, skidding and – in case of a truck-trailer combination – jackknifing. |
| EST | The electronic EST 54 control unit, which has already proven its value in EcoLife transmissions, uses the SAE-J-1939 standard to communicate with drive and vehicle components and also features a diagnostic interface. The software can be adapted to the specific vehicle and telematics solutions offer a variety of additional features. |
| Inverter | The high voltage inverters used by ZF dispose of a nominal voltage of from 350 to 650 volts. They control the asynchronous motors of the ZF drives and are optimized on the electric drive system. |
| On Guard Assist | dvanced Emergency Braking System (AEBS) helps avoid or mitigate rear-end collisions with vehicles ahead. This active safety system assists drivers in recognizing and responding to dangerous driving situations that could lead to a rear-end collision with a moving, stopping or stationary vehicle ahead. |
| On Lane alert | This Lane Departure Warning System is specifically designed for commercial vehicles. Leveraging a forward-looking windshield-mounted camera, the system monitors the vehicle’s position within the lane. When the system detects the vehicle crossing lane markings without a turn signal being activated, the system alerts the driver to take corrective action. By this means, OnLaneALERT can effectively help to prevent road run-offs, side swipes, and head-on collisions. |
| Opti Tire | This tire pressure monitoring system is specifically designed for commercial vehicle. The system offers internal and external wheel sensors, including simple to install strap-mounted sensors, covering all rim sizes and applications. This system constantly monitors the performance of each tire. As soon as a tire issue is detected, OptiTire alerts the driver to help optimize vehicle uptime, tire life and fuel efficiency – making journeys safer and more economical. |
| Short range radar | The corner radar provides the required data for the lane assistant, blind spot assistant, and lane change assistant. It records its surroundings in a range of up to 90 meters in a grid of 20 cylinders and an angle of +/- 75 degrees. Thanks to its 77 GHz RFCMOS technology, it is suitable for automated driving functions. |
| Tail Guard | This active safety technology is the commercial vehicle industry’s first Reversing Collision Avoidance System. The system is designed to detect static and moving objects in the blind spot behind the vehicle. With warning and active braking, the system assists the driver during reversing maneuvers. Aiming for avoiding any impending collision, TailGUARD can automatically bring the vehicle to a complete stop.By this means, this technology can effectively help to maximize safety and vehicle uptime. |
| Vehicle electronic systems | The Vehicle Control Module (VCM) is a central electronic control unit managing the dynamic longitudinal control of a commercial vehicle. It coordinates the powertrain, including engine, transmission and retarder, while also integrating ADAS functions such as Adaptive Cruise Control or Predictive Economic Cruise Control. The Central Vehicle Controller (CVC/MUX) manages the electrical loads throughout the vehicle to orchestrate vehicle functions such as light, wiper or climate control. |
As can be seen the primary product variety that the company has is in the Trailer, HCV and MHCV space. Most products are focused on braking and safety along with air management systems. The company has foray aggressively in electronics, autonomous driving and management analytics and information systems as well.
Financials
The following is the key financials for the company:
| Type | 2017 | 2018 | 2019 | 2020 | 2021 | 2022 |
| Revenue (In M) | 20,675 | 25,733 | 28,541 | 19,296 | 18,635 | 24,785 |
| EBITDA (In M) | 3,262 | 3,986 | 4,099 | 2,515 | 2,058 | 2,695 |
| PAT (In M) | 2,135 | 2,728 | 2,822 | 1,588 | 1,038 | 1,501 |
| EBITDA Margin % | 16% | 15% | 14% | 13% | 11% | 11% |
| PAT Margin % | 10% | 11% | 10% | 8% | 6% | 6% |
| Revenue Growth % | 24% | 11% | -32% | -3% | 33% | |
| CV Sales (Lakhs) | 8.22 | 9.53 | 11.06 | 7.77 | 6.19 | 8.13 |
| CV Sales Growth | 16% | 16% | -30% | -20% | 31% |
Revenue Growth is mostly aligned with the increased CV Sales. The company generally in their conference call says that their revenue growth will be driven by 2 factors – CV Sales increase and increased penetration of ZF products in CV. So overall the revenue growth for the company will be CV Sales + x (x should a function of higher penetration of ZF products).
The following is the break-up of the revenues:
Break up by revenue type:
| Type | 2014 | 2015 | 2016 | 2017 | 2018 | 2019 | 2020 | 2021 | 2022 |
| Export | 40% | 33.60% | 32% | 29.40% | 32% | 30% | 30% | 29.50% | 28.90% |
| OEM | 42% | 49.40% | 52% | 54.40% | 53% | 56% | 52.30% | 53.20% | 54.50% |
| Replacement | 18% | 17% | 16% | 16.20% | 15% | 14% | 17.70% | 17.30% | 16.60% |
Break up by products type:
| Product | Revenue % |
| Braking Control (Air Brakes Valves, EBS and ESG, ABS) | 35% |
| Car Products | 6% |
| Suspension control | 6% |
| Air management systems | 19% |
| Wheel end | 12% |
| Digital services | 3% |
| Transmission automation | 12% |
| Steering control | 1% |
| Electronic control and automation | 6% |
Other Important Information from the annual report:
Some of the other important parameters about the company from the annual reports.
| Type | 2017 | 2018 | 2019 | 2020 | 2021 |
| Revenue (M In INR) | 22,606 | 26,138 | 28,541 | 19,296 | 18,635 |
| Employee | 1,573 | 1,673 | 1,778 | 1,839 | 2,023 |
| EPS | 113 | 144 | 149 | 84 | 55 |
| Revenue per employee (M) | 14.37 | 15.62 | 16.05 | 10.49 | 9.21 |
| Dividend | 7 | 8 | 9 | 10 | 11 |
| Chairman | Lakshminarayan | Lakshminarayan | Lakshminarayan | Lakshminarayan | Lakshminarayan |
| MD | P Kaniappan | P Kaniappan | P Kaniappan | P Kaniappan | P Kaniappan |
| CFO | Rajagopalan Sastry | Rajagopalan Sastry | Rajagopalan Sastry | Rajagopalan Sastry | Rajagopalan Sastry |
| CS | MC Gokul | MC Gokul | MC Gokul | MC Gokul | MC Gokul |
| % increase in salary | 9% | 20% | 11% | 5% | 9% |
| Forex as % of revenues | 26% | 33% | 31% | 45% | 42% |
| Promoter Holding | 75% | 75% | 75% | 75% | 80.43% |
| Promoter Holders | Wabco Asia Private Limited | Wabco Asia Private Limited | Wabco Asia Private Limited | Wabco Asia Private Limited | ZF |
| FII | 0.52% | 1.2% | 2.66% | 2.66% | 0.40% |
| Capex | 73.91 | 103.07 | 102 | 101.5 | 100 |
| Capex Planned for next year | 101.95 | 110 | 119.7 | 104.8 | 118 |
| Attrition | 4.60% | 4.70% | 7.60% | ||
| Total R&D Expenditure | 138.57 | 180.5 | 401.87 | 361.17 | 365.91 |
| % of Turnover | 0.64 | 0.73 | 1.52 | 2.09 | 2.19 |
Industry landscape:
Below is the growth of its key segments – MHCVs and Buses.
Overall CAGR growth for the segment has been almost 0 over the last 5 years.
| Year | Sales in Lakhs – Domestic | Sales in Lakhs – Exports | Total | LCVs | Passenger Carrier LCVs | MHCVs | Buses |
| 2017 | 7.14 | 1.08 | 8.22 | 3.61 | 0.51 | 2.55 | 0.47 |
| 2018 | 8.57 | 0.96 | 9.53 | 4.67 | 0.49 | 3.04 | 0.36 |
| 2019 | 10.07 | 0.99 | 11.06 | 5.64 | 0.52 | 3.51 | 0.4 |
| 2020 | 7.17 | 0.6 | 7.77 | 4.48 | 0.45 | 1.84 | 0.4 |
| 2021 | 5.69 | 0.5 | 6.19 | 3.18 | 0.35 | 1.87 | 0.29 |
| 2022 | 7.2 | 0.93 | 8.13 | 4.02 | 0.44 | 2.37 | 0.37 |
With the overall growth in infrastructure, business activity, logistics, sophistication of demand – the demand for CVs should increase in India. Shriram group expects a 15% CAGR growth for CVs in India and it is generally seen that CV growth is around 1.5 times of the GDP growth.
Some of the key regulations which may help the growth of ZF Global are as follows:
- ABS:
The Ministry of Road Transport and Highways (MoRTH) in India released a notification, where ABS is mandatory for all new passenger cars and two wheeler from April 2019. In 2021, nearly more than 92% of the passenger car sold had been equipped with ABS, owing to the mandatory ABS rule in countries like Japan and Brazil. On April 1, 2015 anti-lock braking systems (ABS) became mandatory for all commercial vehicles in India, following a decision of the Ministry of Road Transport and Highways, a key safety move for the world’s second most populous country with one of the fastest-growing economies. Existing commercial vehicles do not have to be fitted with ABS, but all new manufactures must include it in the new fiscal year.
The first trucks to fall under the new regulations are those that fall under the classification of large goods vehicles, with a gross combination mass (GCM) above 7,700 pounds, along with buses with capacity for 10 or more passengers. ABS was already mandatory in India for semi-tractor trailers and other multi-axle vehicles, including tourist buses, and for smaller trucks carrying hazardous materials.
- Increased axle load norms
First of all increased axle load demand led to improvement in the braking system, but then all the OEMs used the opportunity to launch the BS6 vehicles not only to address the emission aspects, but in improve advancing braking system to meet the requirements of the increased axle load, that is one dimension. We had to upgrade all our braking system products to support the customers. This involved upsizing the compressors or optimizing or increasing the size of the compressors, upgrading the air management system products and in some cases changing the actuators and other elements of the braking system to handle the higher axle load requirement. This is one dimension of the content increase. The other dimension is the driver comfort. We have launched integral pedal unit earlier on a few platforms for some customers, but then a few OEMs decided to use this opportunity to extend it to the entire platform. So, this is an additional content. Third is BS6 regulation, which also demanded certain auxiliary braking systems like exhaust brake, so we had a portfolio of products, for upgrade and then this extended to most of the vehicle platforms in the country.
- Air Management systems:
Due to BS-VI implementation, manufacturers demand more air requirement in vehicles. So, ZF CVCS have updated our air management system products such as compressors, and air processing systems. Advanced braking systems such as auxiliary and exhaust brakes were optional earlier but now, more customers have decided to go for that mandatorily. Certain value-enhancer features are also in demand. They have also partnered two Indian original equipment manufacturers for the connected vehicle programme. We are supporting these demands for software and hardware. We are actually moving into a connected vehicle space with these arrangements. All these have helped us improve Wabco’s content per vehicle.
- Electronic Stability control:
The government is in the process of finalization of implementation of standards for electronic stability control (ESC) and brake assist systems. The notification regarding ESC for buses was issued last year. It is likely to come into force by April 2023.
- Electric mobility braking systems:
India is still at content per vehicle revenue of $600 per vehicle. In Europe, it is $3,200 and in the US, it is $1,500. So, there is a big gap to fill. The regulation in India has to enable growth for new technologies. Another opportunity is electrification. ZF CVCS are already partnering all makers of electric buses in India to make products. Through regulation, electronic stability control for buses will come by 2023. Electric buses have content to the tune of $1,500 but the volume is low. More content will get added from the ZF portfolio as well. Of course, it will be done by ZF.
New energy conservation provides an opportunity to go beyond $1,500. Initially it will be low. Advanced braking system will grow when it comes through regulations and our topline will grow. All safety technology will come only through regulations. There is a lot of discussion going with the regulatory committee. When that happens, it will have a positive impact on our topline.
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