German transmission supplier ZF has just started building production samples of a new electric motor that will be part of Mercedes-Benz new mild hybrid system. Mercedes co-developed the system with BMW and displayed it in several different vehicles shown at last fall's Frankfurt Motor Show. The first production application is expected to be the S400 hybrid which will pair a 3.5L gasoline V-6 with the 15kW electric motor/generator and a lithium ion battery to recapture energy from regenerative braking.

The motors are being manufactured by ZF's Sachs division at a plant in Schweinfurt Germany. ZF claims to be the first company to manufacture hybrid modules in Europe. Full production starts this fall at the rate of 35,000 annually and will eventually be ramped up to 200,000 a year. The Mercedes-BMW mild hybrid sandwiches the motor/generator between the engine and transmission to provide some low speed electric drive, electric power boost at higher speeds, auto start-stop and regenerative energy recapture. ZF currently has eight hybrid development projects with four manufacturers including Mercedes with production launches scheduled over the next four years.

[Source: ZF Friedrichshafen AG]

By now, we have all come to realize that not all hybrids are created equal. Some hybrid drivetrains are designed to maximize fuel mileage, while some cater to the performance crowd. Hybrids are available or are being designed for everything from basic transportation to Sport Utility Vehicles and Luxury cars and even sports cars. So, I was not all that surprised to read that Mercedes has plans for a hybrid version of their range-topper, the S Class sedan. But, I found it a bit odd that the car was to use a small 2.2 liter four-cylinder engine. Now, this engine is a twin turbo Bluetec diesel, but still, the idea of a four cylinder extra large, extra heavy luxury sedan must be met with some surprise, right? Anyway, the drivetrain is apparently capable of hitting 35 miles per gallon, which is very good for a vehicle this size, and it should be capable of even better figures in the smaller E Class and C Class vehicles that will inherit the engine later as well. No word yet on whether these vehicles will make it over to the U.S. or what they will cost.

[Source: Motor Authority]