Customer

Berlin University of Technology

Year

2023

Deliverables

System Development
Software Development
Mechanical Development

Revolutionary electromobility: Europe’s first fully automated e-truck battery changing station offers logistics companies flexibility for heavy commercial vehicles.

Pioneering innovation

On November 23, 2023, the first fully automated e-truck battery changing station was opened in Lübbenau DE. The innovative battery swap system, developed in the “eHaul” research project under the leadership of the Technical University of Berlin, offers a pioneering solution to the challenges posed by the electrification of heavy goods transport.

The central idea is to replace discharged traction batteries of electric commercial vehicles with charged batteries in just a few minutes. This enables logistics companies with interchangeable trucks to achieve a high daily mileage without being tied to loading stops and legally prescribed breaks. Flexibility in distribution is therefore maintained.

The process not only reduces the load on the power grid, but also protects the batteries and requires comparatively low grid connection power. The costs of using a battery swap vehicle are comparable with other drive and charging technologies.

Fully automatic replacement of an exchangeable battery
Vollautomatischer Austausch Einer Wechselbatterie

Vollautomatischer Austausch einer Wechselbatterie

Short exchange time

The eHaul project successfully overcomes technical challenges, including precise handling of vehicle batteries weighing several tons, cooling and communication security. The exchange station enables 440 kWh batteries to be exchanged in around 10 minutes, which enables daily mileage suitable for long-distance transportation. Almost as fast as refueling a diesel truck. The system will be integrated into the day-to-day operations of the logistics companies involved in the coming year in order to gain practical experience.

In summary, the opening shows that battery replacement is a practical and economically viable option for the rapid electrification of heavy commercial vehicles. Particular attention is paid to user flexibility and grid-compatible energy supply.

eTruck battery swap system in practice
Elkw Batteriewechselsystem In Der Praxis

eLkw-Batteriewechselsystem in der Praxis

The Schmidt eCleango 550 is 100 percent electric. The heart of the drive system is the high-voltage battery with a battery capacity of 102 kWh and optionally 153 kWh. The modular high-voltage battery concept is made up of four or six independent battery packs. The individual battery packs are connected in parallel via the central Power Distribution Unit (PDU). Depending on the application, the powerful energy storage units enable operating times of up to 10 hours without recharging.

The drives of all main consumers – traction drive, blower drive, hydraulic pump drive and air conditioning of the driver’s cab – were electrified. Compared to a drive with a combustion engine, the electric drive is more efficient, has optimum performance characteristics and high performance with low maintenance requirements.

An electric rear axle was developed for the traction drive. The maximum torque of 350 Nm is transmitted to the rear wheels via a single-stage gearbox. The 140 kW maximum output of the electric motor enables travel speeds of up to 50 km/h and a climbing ability of up to 30%. The noise level is very pleasant for both the driver and the surroundings. An electric parking brake system with hill start assist guarantees a safe and comfortable start on an incline.

Contribution from Durot Electric

Under the mechanical management of the eHaul project, Durot Electric is responsible for the development, manufacture and implementation of the vehicle-side swap system. A standard vehicle was equipped with specially developed extensions to create a vehicle with automatically replaceable HV batteries.

The battery housing could not be structurally modified due to approval restrictions. For this reason, an add-on housing was developed as an intermediate interface to the battery, which includes a battery-side coupling system for the electrical and fluid connection to the vehicle. A specially developed intermediate connector system, which is actively contacted by means of an actuator, enables the secure connection of all interfaces to the battery. The contact systems are fully removable and comply with the applicable vehicle standards.

The batteries comply with special suspension and fuse specifications. New battery mounts have been developed so as not to affect the ECE R100 approval on the battery side. The suspensions were equipped with a newly developed battery safety system in order to meet the current requirements in the commercial vehicle sector.

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