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How do you make a long-haul diesel truck emit 50% less CO2 without changing a single thing about it? Sounds like a riddle, right? A new pilot solution embraced by BMW Group Logistik and supplied by partner firm Trailer Dynamics here in Germany, though, can do just that. I spoke with Mo Koellner from BMW and Michael Nimtsch from Trailer Dynamics about this tech on a call earlier in the week.

As to the answer to the above riddle: This is a semi-truck trailer that has a massive battery pack (up to 600 kWh) installed in its floor, and that battery powers an electrically driven axle underneath the trailer. The solution isn’t conceptually novel; e-trailers, or electrified trailers, have been on the market in various forms for a number of years now (though the technology is still in a relative stage of infancy). The basic principle is simple, too. By adding a battery-electric driven power source to a diesel tractor-trailer, you reduce the fuel consumption of the diesel portion of the system. In other words, you’ve created a plug-in hybrid-electric big rig. Pretty straightforward, yeah?

What makes Trailer Dynamics’ solution cool is just how “plug and play” it is. In fact, the company says that its electric trailers can work with any truck they are physically capable of hitching to. No trailer-to-truck connection is utilized; the e-trailer operates totally independently. Trailer Dynamics says this makes its product unique* in the space, as most other e-trailer solutions require active communication with the connected truck to enable the electric-assisted drive. BMW is currently testing TD’s solution on its BMW Group Logistik fleet. (*US-based Range Energy also claims to work with basically any truck, and their solution seems quite similar to Trailer Dynamics. We covered them back in May. The biggest distinction I’ve seen is that Trailer Dynamics offers far larger batteries and is designed for use with European tractor-trailer configurations. BMW’s fuel consumption figures also seem to indicate TD’s solution may be more efficient, but it’s hard to know how apples-to-apples these numbers are given the pack size differences.)

The way TD achieves this is down to a proprietary sensor pack that lives in the kingpin of the trailer. There, a computer control model takes input from the sensors (used to monitor various forces on the kingpin) and converts that data into a decision about when and how much power to apply to the electric motors in the axle. The logic of the system takes into account the sort of things you’d expect. For example, if the trailer knows the truck is currently stopped and is beginning a start — when large trucks tend to make use of their fuel most inefficiently — it will apply very substantial power to get the truck rolling. The result is a huge reduction in the amount of diesel used. Similarly, if the system detects the truck is going uphill, electric assist will be applied generously to minimize the effects of an otherwise high fuel consumption situation. According to TD’s website, factors like weather conditions, route topography, and traffic can also be considered, though it was less clear to me how these play in to when the trailer applies power. The system can also be configured to disable itself if the battery capacity reaches a predefined cutoff point (important, as fleet operators ideally want a minimum level of charge guaranteed at any moment).

The system itself is, by the standards of passenger electric vehicles, some very heavy-duty stuff. Battery packs of either 400 kWh or 600 kWh are employed (a 200 kWh unit is coming later), with the 600 kWh configuration being the most desirable among TD’s prospective customers. That’s because the economics of efficiency apparently pay off best for longer routes, where a larger battery is going to be necessary. The electric motor unit outputs up to 580 kW (777 hp), which is impressive, but it’s the insane 13,000 nm of torque that’s doing the heavy lifting (literally). Charging is also pretty damn quick, with the 800V architecture supporting 44 kW AC and up to 350 kW DC fast charging. The supersized figures here make sense when you consider the weights at play — BMW is testing TD’s trailers with a payload of 16 metric tonnes, or over 35,000 pounds. (Specifically, BMW has been using them to haul electric drive units for its passenger cars.)

As for the end efficiency, BMW is seeing fuel consumption lowered by nearly 50% on some of the long-haul routes it’s testing, meaning emissions on those routes are cut in half. Even on shorter routes, the figure is in excess of 45% fuel savings. Because BMW is using 100% carbon-neutral sources to recharge the trailer batteries, it estimates that each e-trailer could cut up to 120 tonnes of CO2 emissions from its fleet each year. For comparison, assuming a “typical” ICE car emits around 5 tonnes of CO2 annually, each trailer optimally utilized is like taking 60 cars off the road. All that is to say: It’s hard to overstate how much fuel a real big truck uses.

BMW has also been testing TD’s trailers with electric trucks, where the system effectively acts as a range extender. Depending on the specific truck, payload, and route, BMW says the range of an electric truck could be extended by a factor of 2-3x, opening up entirely new scenarios for the use of BEV tractor units. In one test, BMW used an unspecified Volvo e-truck in combination with a TD mega trailer to go over 600 km (373 miles) without recharging.

In a perfect world, diesel trucks would be replaced with electric ones wholesale. But in reality, the design principle of trucks as long-life assets means that ICE trucking will stick around a fair bit longer than combustion passenger cars. If we can reach a point where e-trailer systems like Trailer Dynamics’ are minimizing trucking fuel consumption at scale, though, we can still have a real net-positive impact on emissions while that transition occurs. And because this kind of system benefits both ICE and EV tractors (arguably, the latter even more so), this is a scenario where the hybrid step-transition makes much more sense. There’s nothing redundant being engineered here for the sake of ICE trucks; these trailers will retain their usefulness in the age of BEV trucking.

For BMW, the EV trucking side of the equation has an added bonus — the low-liner “mega trailer” configuration it uses for a large amount of its transport fleet greatly limits the range of available EV truck options. Using TD’s mega trailer solution as a range extender is thus an excellent way to work around that challenge. (Mega trailers are a high-capacity trailer class specifically developed for use in the EU, where they remain extremely popular. These space-maximized trailers require a particular class of truck chassis with a very low deck floor for towing, and that leaves very little room for a battery.)

As for the challenges of stuffing a massive battery in the bottom of an already super-heavy-laden trailer? They’re not nonexistent. According to BMW, TD’s solutions are best for shipping in “cubed out” configurations — that is, utilizing the maximum volume of a container, not its maximum weight. And sure, the battery cannibalizes some of the available space for cargo. But, over time and with the evolution and refinement of the system (weight reduction is one of TD’s immediate goals), greater and greater payloads will become feasible. Human behavior is another big factor to consider. Suppose a tractor operator is still driving like a leadfoot. In that case, it’s possible to mitigate a fair bit of the system’s fuel savings (BMW saw fuel consumption variability of up to 20% during testing based on driver). On the economics, BMW believes that e-trailers will significantly lower fleet operating costs, offsetting initially higher acquisition costs for the equipment.

Down the road, TD suggests it could also start using its tech to assist in the on-road safety of tractor-trailers, applying power or engine braking force for stability management (for example, if a truck is in danger of jackknifing). Right now, the company is just getting started, and currently has seven trailers in operation (an eighth was just delivered).

While cleaning up our passenger cars will have a real effect on global CO2 emissions, the impact of trucking transport is something we should all be considering, too. According to data from the IEA, road freight accounts for 30% of all global transportation emissions, making it the second-largest contributor behind passenger vehicles — and by a wide margin. (For comparison, all air and sea transit contribute just above 10% of global emissions each. Rail sits at a measly 1%.)

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Mitsubishi Fuso cleans up, putting 89 electric garbage trucks to work in Greece

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Mitsubishi Fuso cleans up, putting 89 electric garbage trucks to work in Greece

The Greek cities of Athens and Thessaloniki are popular tourist spots, and those tourists are about to breathe a little bit easier – literally! – thanks to nearly 90 new electric garbage trucks from Mitsubishi Fuso.

The Daimler-owned Mitsubishi Fuso brand has been making big moves since export of its newest electric eCanter medium duty truck kicked off earlier this year. First expanding to Hong Kong, and now taking orders in the EU.

“Thanks to its compact dimensions and high chassis load capacity, the electric Next Generation eCanter is ideal for waste disposal companies that drive on narrow roads,” says Florian Schulz, Head of Sales, Marketing and Customer Services. “In addition, the vehicle is locally emission-free and quiet, so that garbage can be emptied early in the morning in densely populated areas. This makes it particularly suitable for municipal applications.”

One of the most important goals the cities’ governments had was to quiet down the garbage collection process. To that end, Greek body manufacturer KAOUSSIS has put a lot of development work into the upfit body to quiet the hydraulic and compaction actions. The company is calling its refuse body “the first of its kind,” creating a market advantage for the electric eCanter while meeting all EU technical regulations for operating waste disposal vehicles with standing personnel.

The hydraulic system employs proportional, electro-hydraulically operated directional valves that operate at a maximum pressure of 180 bar. KAOUSSIS says it’s specially designed for EVs, and is compatible with garbage bins between 80 and 390 liter (aka: really big) capacities. The lift also features a dynamic weighing system that records the weight of the waste with an accuracy of up to ±0.5 kg (about a pound).

“We have had a very close cooperation with KAOUSSIS for over 30 years,” says Antonios Evangeloulis, Director of Sales & Marketing of the Greek importer & general agent for Daimler truck products and services Star Automotive Hellas. “All the necessary tools, safety measures, technicians, training and certifications are in place and we are able to offer excellent after-sales support for these vehicles. Overall, it was an exciting project that we were able to realize together.”

Forty of the new electric refuse trucks are expected to be deployed by the end of November, with the balance expected to be delivered over the course of 2025.

Electrek’s Take

Mitsubishi Fuso eCanter; via Daimler Trucks.

Electrifying the commercial truck fleet is a key part of decarbonizing city truck fleets – not just here in the US, but around the world. I called the eCanter, “a great product for moving stuff around densely packed city streets,” and garbage is definitely “stuff.”

Here’s hoping we see more “right size” electric solutions like this one in small towns and tight urban environments stateside somewhat sooner than later.

SOURCE | IMAGES: Daimler Trucks, via Charged EVs.

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Italian DC fast charger maker Alpitronic enters the US market [video]

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Italian DC fast charger maker Alpitronic enters the US market [video]

Electrek‘s Seth Weintraub went to Alpitronic America’s new HQ to speak with CEO Mike Doucleff about its plans to roll out its ultra-fast chargers across the US.

Bolzano, Italy-based Alpitronic was founded in 2009, and it specializes in the development and production of DC fast chargers. The global company’s best-known product line is the Hypercharger, an ultra-fast EV charging station that can deliver charging power from 50 kW to 400 kW, depending on the model.

Alpitronic Americas recently announced an agreement with Mercedes-Benz High-Power Charging to become the first DC fast-charging network to deploy Hypercharger 400 units at scale in the US.

Alpitronics Americas’ new headquarters’ 68,000-square-foot office and industrial space in Charlotte, North Carolina, includes a diagnostics laboratory and repair center, a spare parts warehouse, a training center, and space for as many as 300 employees.

The Bolzano, Italy-based company’s Hyperchargers achieve, on average, an efficiency rate greater than 97.5%, and that its repair and service network can service chargers anywhere in the US.

Alpitronic cofounder and CEO Philipp Senoner said, “As a natural part of Alpitronic’s growth, we are anxious to expand our industry-leading Hypercharger network from Europe, where we are market-share leader, to North America. We are pleased with the talent we are finding in North Carolina and look forward to setting a new standard for the EV charging network in the US.”

Alpitronic chargers support all EV brands. Pre-production units have been tested publicly in Rock Hill, SC, and Portland, OR. The first US-built, public chargers are expected to be installed and available in October.

Seth and Mike Doucleff discuss what Aliptronic’s main driver was to come to the US, what attracted them to Charlotte, and what the company thinks the future of DC fast chargers is in the US, among other things. Their conversation begins at 00:41 on the Electrek podcast below:


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Volvo CE rolls out some new hotness at Volvo Days 2024 [part 1]

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Volvo CE rolls out some new hotness at Volvo Days 2024 [part 1]

This week, Volvo Group held its once-every-three-years “Volvo Days” event in Shippensburg, PA for the first time since the pandemic, showing off tons (literally!) of new equipment, new trucks, and new concepts – including a couple of “world’s first” debuts.

What is Volvo Days? That might require a bit of background …

The heavy equipment world operates on something of a three-year cycle. ConExpo, the industry’s biggest trade show, happens every three years. That sets the tone, with companies showing off all their hottest concepts and forward-thinking new projects. That’s year 1. Year 2 is typically when shows like Volvo Days typically take place, with manufacturers rolling out the production versions of the concepts they showed at ConExpo and inviting a mix of dealers, end-users, and journalists in to try out some of what got showed at ConExpo. Year 3 is more insular, with the manufacturers bringing in salespeople to get them trained on new products and prepare them for how to talk about what the company is planning to show at next year’s ConExpo.

ConExpo was last year, so this year we get Volvo Days – for the first time since 2018, in fact, since the 2021 event was canceled due to COVID. That makes this the first Volvo Days in six years … and expectations were high.

The kickoff

Volvo Days, night 1; kickoff.

Volvo kicked off the week’s events with a drone display highlighting the company’s construction equipment history – appropriate, given that the event was held at Volvo CE’s Pennsylvania engineering and production campus. The drone show was followed by a genuinely impressive, highly choreographed equipment ballet that featured new electric equipment shown for the first time in North America, as well as the new-for-2025 Volvo VNL and Mack MD Electric trucks doing some heavy lifting and hauling.

The show lasted well over thirty minutes, and it was impossible for me to keep track of everything that was happening, but you can get a sense of it in the video (above).

Compact electric equipment

Volvo had its new, in-production L20/120 Electric wheel loader and ECR25 Electric excavator front and center in its reception center, along with information highlighting their competitive advantages in the compact equipment space.

The best thing about Volvo Days, however, isn’t that they have interesting vehicles on display – it’s the fact that nearly every one of those interesting vehicles is available to experience first hand … including the 30-ton EC230 Electric excavator.

Volvo Electric excavators with Steelwrist; photo by the author.

All the electric excavators (even the mini) were incredibly smooth and quiet, with noticeably fewer vibrations than their diesel counterparts … which we also got to play with.

That said, I’m not a “real” equipment operator, which means my seat of the pants impressions are probably worth less than those of the people who use these things every day. That’s why I was glad to have Mike Switzer, my co-host on The Heavy Equipment Podcast, along for the ride.

“It’s really impressive, and the articulation on the Steelwrist is incredible,” Mike told me, after hopping out of the demo EC230. “I’ve seen it before, obviously, but I’ve never had a chance to use it. I think every municipality needs to take a look at that.”

Electric compaction

Volvo electric compactors; image by the author.

Over on the compaction side, Volvo had its DD25 Electric vibrating drum compactor on display – where the all-electric tandem roller was joined by two all-new siblings being shown off for the first time ever: a pre-production DD15 Electric “mini” compactor prototype seemingly designed for sidewalks and driveways, and the TC13 Electric trench compactor.

The TC13 Electric is designed as a walk-behind unit that uses its heavy batteries to provide the compaction mass – but those heavy batteries won’t get depleted in the hour or so of operation that most trench compactors see on a busy day. To keep the little TC13 useful throughout the day, Volvo gave it a pair of 110 and 220V outlets.

TC13 power outlets; photo by the author.

Specs weren’t released, but Volvo’s compaction brand manager claimed those outlets were more than capable of keeping the rest of the job site’s battery-operated tools running all day long, and even packed enough juice (in a pinch) to power a portable office, table saw, or drill press.

“Did you see his face when I asked if it could run an arc welder?” asked Mike, smiling. “He said, ‘It’s not something we’d advise,’ but you could tell he liked that question.”

Yeah, he did!

Electrek’s Take

Jo Borrás looking for prizes; photo by Jefferson Yin.

Somewhere around the twenty minute mark of the “equipment ballet” show, something broke inside my brain. I think it was the sparks flying off the bucket when the L20 Electric scooped up a few thousand pounds of gravel and sand at full speed, scraping its bucket along the ground. Maybe it was the hydrogen-powered articulated loader, or the open bar.

Regardless, one thing that was made very clear at Volvo Days ’24 is that, while other companies are still developing the initial entries into the electric commercial vehicle space, Volvo has not just a full line of products – but an expanding line of products, with the company entering new spaces specifically because of the unique advantages electric offers.

As Volvo’s North American President, Scott Young, explains, the future is electric, and Volvo’s vision for the future has the company firmly in the leadership position … but more on that in part 2.

ORIGINAL CONTENT FROM ELECTREK.

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