Using live driving data, German firm ZF can create an individual maintenance plan for buses that is tailored to the actual condition of the transmission.

Fault diagnostics are possible via digital remote access, so unnecessary workshop visits can be avoided and operating times increased.

Thanks to digital connectivity via the ZF Bus Connect intelligent fleet management system, remote vehicle data access can be turned into actionable service-related insights. In the future, maintenance schedules could be based on the actual condition of the vehicle.

Public transport plays a key part in the sustainable transformation of the transport sector. To increase this positive impact, as well as ensure the best service quality for passengers, buses must spend as much time as possible on the road and as little as necessary in the workshop.

This digital service concept helps with these problems. Called ZF Health Check, it is specially adapted to the ZF EcoLife automatic transmission, which is used by transport operators worldwide in city buses and regular-service buses.

This uses numerous types of sensor data registered in the transmission system during vehicle operations, for example engine speed, gear step, oil temperature and oil pressure. These data are frequently transferred over-the-air to a dedicated analytics service operating in the ZF Cloud, where individual service-relevant insights are determined. In turn, those insights result in recommendations for action for the bus operator or service company.

For example, the operator can make the best use of the service life of transmission oil, because the oil is not changed at a predefined mileage, which could be too early. The bus thus stays on the road longer and availability increases. Even if the bus has to go to the workshop, downtime is reduced because spare parts or materials can be provided in advance thanks to the vehicle data. The working time can also be better planned. And if the company’s own workshop cannot find the fault, the fleet operator can call in external service experts and give them access to the Health Check portal.

Another advantage is bus fleet operators receive early warnings of impending breakdowns. This is because damage does not usually occur suddenly, but rather can be anticipated, for example by deviations in oil pressure or temperature. If the operator then takes the vehicle to the workshop, not only is the repair often less expensive because no consequential damage has occurred, but the problems associated with a breakdown are also eliminated, such as transport of the passengers, use of a replacement bus or taking the broken-down vehicle to the workshop.

“With ZF EcoLife we already enable hundreds of bus operators around the globe to perform more efficiently,” said Philippe Colpron, head of ZF Aftermarket. “With our ZF Health Check offering, leveraging remote vehicle data access and predictive analytics, we can now accompany our fleet customers even one step further towards zero downtime and paving the way for a sustainable aftermarket.”

ZF Health Check is available immediately to users of ZF Bus Connect Premium fleet telematics. ZF is planning the integration of additional components into Health Check. In addition to Health Check, ZF Bus Connect offers functions for operational optimisation of bus fleets such as a live view of the entire vehicle fleet, insight into optimisation potential with regard to fuel and energy consumption, driver behaviour, or wear and tear of technical components such as brakes. It generates reports on compliance or as a basis for tax-related proofs in public transport.