{"id":11279,"date":"2021-05-27T12:57:22","date_gmt":"2021-05-27T10:57:22","guid":{"rendered":"https:\/\/advancedfleetmanagementconsulting.com\/eng\/?p=11279"},"modified":"2021-05-27T12:57:22","modified_gmt":"2021-05-27T10:57:22","slug":"fleets-45","status":"publish","type":"post","link":"https:\/\/advancedfleetmanagementconsulting.com\/eng\/2021\/05\/27\/fleets-45\/","title":{"rendered":"How fleets can benefit from electric axles"},"content":{"rendered":"<p style=\"text-align: justify;\"><span style=\"color: #0000ff;\">Electric axles are beginning to make their way to medium and heavy duty vehicles, giving fleets an opportunity to reduce maintenance requirements, fuel consumption, and emissions.<\/span><\/p>\n<div id=\"content-body-21081923\" class=\"page-contents__content-body\">\n<p style=\"text-align: justify;\"><span style=\"color: #0000ff;\">Manufacturers of axles and other drivetrain components are making a bigger push into the electric vehicle (EV) market, and we\u2019re not just talking about passenger vehicles anymore. From medium duty trucks all the way through Class 8, electrification can help fleets lower both emissions and operating costs \u2013 without adding complexity for drivers or technicians.<\/span><\/p>\n<p style=\"text-align: justify;\"><span style=\"color: #0000ff;\">\u201cDana has been working on electrification for quite a while now,\u201d says Harry Trost, senior manager of product planning for Dana\u2019s Commercial Vehicle Group, a leading drivetrain and propulsion systems provider. The company put its first electric axle into production a little over a year ago in China, resulting from a joint venture with Dongfeng Dana Axle Co., Ltd. That factory is capable of producing 800,000 electric axles per year.<\/span><\/p>\n<div class=\"teads-adCall\" style=\"text-align: justify;\"><\/div>\n<p style=\"text-align: justify;\"><span style=\"color: #0000ff;\">China is a great example of how a market for electrification can quickly evolve. According to Trost, the Chinese market started with the easiest way to integrate an electric propulsion system into a vehicle: a central-mount, direct-drive solution where a motor is connected to a traditional driveshaft and axle. Roughly 95 percent of the Chinese market continues to rely on that solution. However, the technology is evolving toward a more efficient, lighter-weight and lower-cost electric axle that is part of an integrated system.<\/span><\/p>\n<p style=\"text-align: justify;\"><span style=\"color: #0000ff;\">Dana\u2019s recent acquisition of controlling interest in TM4 Inc. gives Dana the capability of producing all core components of a fully integrated electric drive system:<\/span><\/p>\n<ul style=\"text-align: justify;\">\n<li><span style=\"color: #0000ff;\">Electrified drivetrain components (including electric axles, which Dana refers to as e-Axles)<\/span><\/li>\n<li><span style=\"color: #0000ff;\">Motors, power inverters, and controls components<\/span><\/li>\n<li><span style=\"color: #0000ff;\">Thermal management components<\/span><\/li>\n<\/ul>\n<p style=\"text-align: justify;\"><span style=\"color: #0000ff;\">In addition to TM4, Dana has acquired SME Group, a manufacturer of lower-voltage motors for accessory drive applications. Dana has also acquired Oerlikon Drive Systems, which gives Dana additional competency in precision helical gearing and planetary gearing, as well as transmissions.<\/span><\/p>\n<p style=\"text-align: justify;\"><span style=\"color: #0000ff;\">\u201cMany of these e-Axles will also incorporate multi-speed transmission approaches,\u201d Trost says.<\/span><\/p>\n<p style=\"text-align: justify;\"><span style=\"color: #0000ff;\">Speaking of transmissions, some major news broke in April when it was announced that Allison Transmission was acquiring the Electric Vehicle Systems division of AxleTech. Allison Transmission is a leading manufacturer of automatic transmissions for medium and heavy duty commercial vehicles, as well as hybrid propulsion systems for city buses. AxleTech\u2019s CEO, Bill Gryzenia, says the integrated electrification solutions AxleTech has developed can now enter a new phase of development and commercialization with Allison Transmission.<\/span><\/p>\n<p style=\"text-align: justify;\"><span style=\"color: #0000ff;\">\u201cAllison recognized the benefit of these electric axle products by way of the space between the wheels for batteries and other system components, and believes this is a true differentiator,\u201d says Mike Foster, chief technology officer for Allison Transmission. \u201cWe look forward to being a part of the big opportunity for the electrification of medium and heavy duty fleet vehicles. An OEM\u2019s needs are based on weight and application, so central drive units, electric axles, or a combination of the two will be able to support the needs of many fleets.\u201d<\/span><\/p>\n<p style=\"text-align: justify;\"><span style=\"color: #0000ff;\">Another example of an integrated electric axle comes from Meritor, a supplier of drivetrain, mobility, braking, and aftermarket solutions for the commercial and industrial markets. The company is marketing its eAxle Integrated Electric Drivetrain under its Blue Horizon brand. The system comprises:<\/span><\/p>\n<ul style=\"text-align: justify;\">\n<li><span style=\"color: #0000ff;\">Power Control &amp; Accessory Subsystem (PCAS) \u2013 the brains of the operation that links all drive system components together<\/span><\/li>\n<li><span style=\"color: #0000ff;\">Motor Drive System (MDS) \u2013 consists of an electric motor(s), automated manual transmission, EV-optimized drive axle and brakes, and shifting software<\/span><\/li>\n<li><span style=\"color: #0000ff;\">Energy Storage System (ESS) \u2013 Nickel Manganese Cobalt (NMC) battery pack and battery management system packaged in a modular design\u00a0<\/span><\/li>\n<\/ul>\n<p style=\"text-align: justify;\"><span style=\"color: #0000ff;\">Meritor made news itself this spring when the company announced it would be supplying the Port of Long Beach and the Port of Oakland with electric drivetrain systems for 38 terminal trucks. T.J. Reed, Meritor\u2019s vice president of front drivetrain and electrification, says the contract validates Meritor\u2019s position as a leader in electric drivetrains as the company works toward the commercialization of battery-electric vehicles.<\/span><\/p>\n<p style=\"text-align: justify;\"><span style=\"color: #0000ff;\">A startup company that is capitalizing on integrated electric axle technology is Hyliion. The company\u2019s name is derived from its flagship product, a hybrid lithium-ion solution called the 6X4HE System. This system allows fleets to hybridize any Class 8 truck from any manufacturer. Featuring a modular design for easier installation and servicing, the 6X4HE System includes:<\/span><\/p>\n<ul style=\"text-align: justify;\">\n<li><span style=\"color: #0000ff;\">Battery pack<\/span><\/li>\n<li><span style=\"color: #0000ff;\">Control unit<\/span><\/li>\n<li><span style=\"color: #0000ff;\">Thermal management system<\/span><\/li>\n<li><span style=\"color: #0000ff;\">Electric axle<\/span><\/li>\n<li><span style=\"color: #0000ff;\">Co-pilot display<\/span><\/li>\n<li><span style=\"color: #0000ff;\">Aerodynamics\u00a0<\/span><\/li>\n<\/ul>\n<p style=\"text-align: justify;\"><span style=\"color: #0000ff;\">\u201cWe\u2019ve been in development for a little over three years now,\u201d says Thomas Healy, founder and CEO of Hyliion. \u201cOver the past six months or so, we\u2019ve begun shipping revenuable units to fleets. We had some beta test units with some fleets prior to that.\u201d<\/span><\/p>\n<p style=\"text-align: justify;\"><span style=\"color: #0000ff;\">Dana has been supplying Hyliion with conventional axles (the S23190) for use in the Hyliion system. Hyliion then acts as the total system integrator and software provider. But what started out as a routine buyer-seller relationship has blossomed into more. Dana has become the lead investor in Hyliion\u2019s most recent round of financing.<\/span><\/p>\n<p style=\"text-align: justify;\"><span style=\"color: #0000ff;\">\u201cWe\u2019ve now been able to cement an even stronger relationship so we can partner on whatever future technologies exist with respect to the electric axle, motors, inverters, and other electric components,\u201d Healy says.<\/span><\/p>\n<p style=\"text-align: justify;\"><span style=\"color: #0000ff;\">In addition to Hyliion\u2019s hybrid solution, Dana manufactures e-Axles for fully electric vehicles. Dana is currently working with leading truck manufacturers on future projects to incorporate Dana e-Axles into their own electric and hybrid solutions.<\/span><\/p>\n<h3 style=\"text-align: justify;\"><span style=\"color: #0000ff;\">Do electric axles make sense for fleets?<\/span><\/h3>\n<p style=\"text-align: justify;\"><span style=\"color: #0000ff;\">When a vehicle goes fully electric, it consumes zero fuel and produces zero emissions. Even when moving to a hybrid solution such as Hyliion\u2019s, fleets can realize significant environmental and cost savings. Dana provides a Total Cost of Ownership Calculator to help fleets understand the financial benefits of electrification. Fleets can check it out at <a style=\"color: #0000ff;\" href=\"https:\/\/apps.dana.com\/commercial-vehicles\/tco\/\" target=\"_blank\" rel=\"noopener noreferrer\">apps.dana.com\/commercial-vehicles\/tco\/<\/a>.<\/span><\/p>\n<p style=\"text-align: justify;\"><span style=\"color: #0000ff;\">Dana\u2019s Trost says fleets can also enjoy efficiency gains as a result of an electric axle configuration.<\/span><\/p>\n<p style=\"text-align: justify;\"><span style=\"color: #0000ff;\">\u201cOn the classic Class 8 tractor-trailer, there is a 6&#215;4 drive axle, meaning that both rear axles are driving with a connecting interaxle driveshaft,\u201d Trost explains. \u201cWith an electric vehicle, an OEM can now use Dana\u2019s S175 high-efficiency drive axle that supports 6&#215;2. Instead of having a rear axle that is a non-powered tag axle, Dana\u2019s new eS6200r e-Axle can be installed to provide the efficiency of a 6&#215;2 with 6&#215;4 tractive effort. This e-Axle fits into existing suspensions in the marketplace.\u201d<\/span><\/p>\n<p style=\"text-align: justify;\"><span style=\"color: #0000ff;\">Integrated electric axles can offer additional benefits for fleets. \u201cOne limitation with a conventional drive axle is that you can probably go up to the low 7:1 ratio, and then you can\u2019t incorporate much more high-numerical gearing,\u201d Trost points out. \u201cWith an integrated approach, you have more flexibility on ratio choices, which leads to the benefit of being able to select a more optimized motor and inverter for an integrated approach. So improved efficiency is an immediate benefit. Then, because of the smaller motor, there is the benefit of reduced weight.\u201d<\/span><\/p>\n<p style=\"text-align: justify;\"><span style=\"color: #0000ff;\">For fleets that still are a little skittish about relying solely on battery power, Hyliion\u2019s Healy says hybridization is a good option \u2013 especially for long-haul trucks.<\/span><\/p>\n<p style=\"text-align: justify;\"><span style=\"color: #0000ff;\">\u201cFor Class 8 long-haul trucking, you\u2019re putting tremendous amounts of miles on every year,\u201d Healy says. \u201cWith a passenger car, you\u2019re typically making a 30-mile commute to work every day, and then parking in the garage and recharging every night. So full electrification is catching on more in the passenger vehicle industry. That said, we think it will still be quite a while before Class 8 trucks can go fully electric.\u201d<\/span><\/p>\n<p style=\"text-align: justify;\"><span style=\"color: #0000ff;\">In the meantime, the hybrid approach can make a lot of sense. According to Healy, an electric axle in a hybrid vehicle can help a fleet save 5 to 10 percent on fuel in rolling terrain areas, and 10 to 15 percent in more hilly areas. When a truck reaches an uphill climb, the electric axle kicks in and helps relieve some of the load placed on the engine. Then, when travelling downhill, that same axle can use regenerative braking to charge the battery pack. As a result, the truck never has to be plugged in to recharge, which is a big efficiency and convenience gain for fleets.<\/span><\/p>\n<p style=\"text-align: justify;\"><span style=\"color: #0000ff;\">With an electric axle, electric power from the truck is transferred to a battery bank, control box, and cooler, and then to the rear axle with an integrated motor. Hyliion\u2019s Healy says it is difficult to put a drive system on a steer axle, so the Hyliion system is not designed for that right now. Instead, it focuses on the two rear axles of the tractor.<\/span><\/p>\n<p style=\"text-align: justify;\"><span style=\"color: #0000ff;\">Since the Hyliion system is a hybrid system, the truck still needs diesel power. Thus, a driveshaft is still needed to run from the transmission to the front axle. However, that is where the driveshaft stops. The electric axle is completely independent and located at the rear. Fleets must also mount a battery box, cooling system, and controls box to the frame of the truck.<\/span><\/p>\n<p style=\"text-align: justify;\"><span style=\"color: #0000ff;\">\u201cAll of these components connect together and work in unison,\u201d Healy says with respect to the Hyliion system. \u201cWhen the truck accelerates, we are passively reading the CAN bus of the truck so we know how hard the engine is working and how much fuel is being consumed. We also have our own algorithm with our software that is analyzing the data coming off of the truck. Our system then determines when it is appropriate to kick in and supplement what the engine is already doing.\u201d<\/span><\/p>\n<p style=\"text-align: justify;\"><span style=\"color: #0000ff;\">A side benefit of the Hyliion hybrid system is that a driver can use the unit that cools the system batteries to function as an auxiliary power unit (APU) when the driver is sleeping in a rest area. That could potentially spare a fleet the need to invest in a separate APU.<\/span><\/p>\n<p style=\"text-align: justify;\"><span style=\"color: #0000ff;\">In addition to long-haul, Trost says there are many other fleet applications where an integrated electric axle can be beneficial \u2013 from Class 4 all the way through the variants of Class 8. Dana is developing a full lineup of e-Axles for 6- to 12-meter buses, as well as medium duty vehicles such as city delivery vehicles, incorporating Dana\u2019s eS9000r e-Axle for Class 4, 5, and 6. An e-Axle like the one put in the Hyliion solution can be leveraged for Classes 6 and 7. Dana is also developing a solution for Class 8 for severe-duty applications like refuse vehicles.<\/span><\/p>\n<p style=\"text-align: justify;\"><span style=\"color: #0000ff;\">In other words, fleets of all shapes and sizes could see more electrification in coming years \u2013 perhaps sooner than later.<\/span><\/p>\n<h3 style=\"text-align: justify;\"><span style=\"color: #0000ff;\">Maintenance made easier<\/span><\/h3>\n<p style=\"text-align: justify;\"><span style=\"color: #0000ff;\">Hyliion\u2019s Healy says the nice thing with electric systems is that wear and tear is limited. There are no pistons or cylinders. There is an electric motor that spins, but then just a battery pack behind it.<\/span><\/p>\n<p style=\"text-align: justify;\"><span style=\"color: #0000ff;\">\u201cYou just drive until the batteries run out of life,\u201d Healy says. Any battery pack has a pre-determined life. Hyliion is using one of the more advanced on the market, generally providing a seven- to nine-year life.<\/span><\/p>\n<p style=\"text-align: justify;\"><span style=\"color: #0000ff;\">\u201cVery little maintenance is required beyond that,\u201d Healy adds. \u201cOn the Hyliion system, you do need to swap out the ATF (automatic transmission fluid) in the motor once a year. Also, be sure to top off the antifreeze as needed.\u201d<\/span><\/p>\n<p style=\"text-align: justify;\"><span style=\"color: #0000ff;\">Dana\u2019s Trost says most motors and inverters are relatively maintenance-free. \u201cSome have bearings that are greased and are literally lubed for life,\u201d he points out. \u201cSome solutions in the market have oil-cooled motors, so fleets could see sharing of oil as well as lubricants for gears and bearings. Many solutions have traditional oil change maintenance procedures. One new thing to periodically check are the electrical cables to make sure everything is staying tight. Still, it\u2019s a significant overall decrease in the amount of maintenance needed.\u201d<\/span><\/p>\n<p style=\"text-align: justify;\"><span style=\"color: #0000ff;\">An electrified drivetrain could dramatically change the industry, and that change has taken a big step forward in recent months. The benefits for a fleet are plenty, from reduced weight and fuel consumption to simplified maintenance and reduced emissions. As the technology evolves and more OEMs begin to adopt these types of integrated electric solutions, even bigger changes could be on the horizon.<\/span><\/p>\n<p style=\"text-align: justify;\"><span style=\"color: #0000ff;\">\u201cWe expect that vehicles themselves are likely to change,\u201d Trost says. \u201cAn electric axle opens up new possibilities with respect to vehicle design architectures. For example, maybe a delivery van would like to have a lower floor. Now you don\u2019t have to restrain the vehicle architecture to the traditional frame rails or the traditional extended-nose cab. There are a lot of new possibilities that probably haven\u2019t even been thought about yet \u2013 possibilities that these new integrated electric powertrains are going to enable.\u201d<\/span><\/p>\n<\/div>\n<p>&nbsp;<\/p>\n<p>By <span class=\"page-attribution__content-name\"><a href=\"https:\/\/www.fleetmaintenance.com\/home\/contact\/20987851\/gregg-wartgow\">Gregg Wartgow<\/a><\/span><\/p>\n<p><span class=\"posted-by\">Source: <a href=\"https:\/\/www.fleetmaintenance.com\" target=\"_blank\" rel=\"noopener noreferrer\">https:\/\/www.fleetmaintenance.com<\/a><\/span><\/p>\n<div class=\"g-cols wpb_row type_default valign_top vc_inner vc_custom_1585038969469\">\n<div class=\"vc_col-sm-12 wpb_column vc_column_container\">\n<div class=\"vc_column-inner\">\n<div class=\"wpb_wrapper\">\n<div class=\"w-post-elm post_content\">\n<div class=\"g-cols wpb_row type_default valign_top vc_inner vc_custom_1585038969469\">\n<div class=\"vc_col-sm-12 wpb_column vc_column_container\">\n<div class=\"vc_column-inner\">\n<div class=\"wpb_wrapper\">\n<div class=\"w-post-elm post_content\">\n<div class=\"g-cols wpb_row type_default valign_top vc_inner vc_custom_1585038969469\">\n<div class=\"vc_col-sm-12 wpb_column vc_column_container\">\n<div class=\"vc_column-inner\">\n<div class=\"wpb_wrapper\">\n<div class=\"w-post-elm post_content\">\n<h3 style=\"text-align: center;\"><a href=\"https:\/\/advancedfleetmanagementconsulting.com\/eng\/consultancy\/\" target=\"_blank\" rel=\"noopener noreferrer\"><strong>CUT COTS OF THE FLEET WITH OUR AUDIT PROGRAM<\/strong><\/a><\/h3>\n<p><a href=\"https:\/\/advancedfleetmanagementconsulting.com\/eng\/consultancy\/\"><img loading=\"lazy\" class=\"wp-image-5377 aligncenter\" src=\"https:\/\/advancedfleetmanagementconsulting.com\/eng\/wp-content\/uploads\/sites\/3\/2020\/04\/nueva-ley-auditoria.jpg\" sizes=\"(max-width: 858px) 100vw, 858px\" srcset=\"https:\/\/advancedfleetmanagementconsulting.com\/eng\/wp-content\/uploads\/sites\/3\/2020\/04\/nueva-ley-auditoria.jpg 2000w, https:\/\/advancedfleetmanagementconsulting.com\/eng\/wp-content\/uploads\/sites\/3\/2020\/04\/nueva-ley-auditoria-300x200.jpg 300w, https:\/\/advancedfleetmanagementconsulting.com\/eng\/wp-content\/uploads\/sites\/3\/2020\/04\/nueva-ley-auditoria-1024x682.jpg 1024w\" alt=\"\" width=\"858\" height=\"572\" \/><\/a><\/p>\n<p style=\"text-align: justify;\">The audit is a key tool to know the overall status and provide the analysis, the assessment, the advice, the suggestions and the actions to take in order to cut costs and increase the efficiency and efficacy of the fleet. We propose the following fleet management audit.<\/p>\n<h3 style=\"text-align: center;\"><a href=\"https:\/\/advancedfleetmanagementconsulting.com\/eng\/consultancy\/\" target=\"_blank\" rel=\"noopener noreferrer\"><strong>FLEET MANAGEMENT AUDIT<\/strong><\/a><\/h3>\n<\/div>\n<\/div>\n<\/div>\n<\/div>\n<\/div>\n<\/div>\n<\/div>\n<\/div>\n<\/div>\n<\/div>\n<\/div>\n<\/div>\n<\/div>\n<\/div>\n<\/div>\n","protected":false},"excerpt":{"rendered":"<p>Electric axles are beginning to make their way to medium and heavy duty vehicles, giving fleets an opportunity to reduce maintenance requirements, fuel consumption, and emissions. Manufacturers of axles and other drivetrain components are making a bigger push into the electric vehicle (EV) market, and we\u2019re not just talking about passenger vehicles anymore. From medium&#8230;<\/p>\n","protected":false},"author":3,"featured_media":11280,"comment_status":"open","ping_status":"open","sticky":false,"template":"","format":"standard","meta":[],"categories":[18],"tags":[28],"_links":{"self":[{"href":"https:\/\/advancedfleetmanagementconsulting.com\/eng\/wp-json\/wp\/v2\/posts\/11279"}],"collection":[{"href":"https:\/\/advancedfleetmanagementconsulting.com\/eng\/wp-json\/wp\/v2\/posts"}],"about":[{"href":"https:\/\/advancedfleetmanagementconsulting.com\/eng\/wp-json\/wp\/v2\/types\/post"}],"author":[{"embeddable":true,"href":"https:\/\/advancedfleetmanagementconsulting.com\/eng\/wp-json\/wp\/v2\/users\/3"}],"replies":[{"embeddable":true,"href":"https:\/\/advancedfleetmanagementconsulting.com\/eng\/wp-json\/wp\/v2\/comments?post=11279"}],"version-history":[{"count":1,"href":"https:\/\/advancedfleetmanagementconsulting.com\/eng\/wp-json\/wp\/v2\/posts\/11279\/revisions"}],"predecessor-version":[{"id":11281,"href":"https:\/\/advancedfleetmanagementconsulting.com\/eng\/wp-json\/wp\/v2\/posts\/11279\/revisions\/11281"}],"wp:featuredmedia":[{"embeddable":true,"href":"https:\/\/advancedfleetmanagementconsulting.com\/eng\/wp-json\/wp\/v2\/media\/11280"}],"wp:attachment":[{"href":"https:\/\/advancedfleetmanagementconsulting.com\/eng\/wp-json\/wp\/v2\/media?parent=11279"}],"wp:term":[{"taxonomy":"category","embeddable":true,"href":"https:\/\/advancedfleetmanagementconsulting.com\/eng\/wp-json\/wp\/v2\/categories?post=11279"},{"taxonomy":"post_tag","embeddable":true,"href":"https:\/\/advancedfleetmanagementconsulting.com\/eng\/wp-json\/wp\/v2\/tags?post=11279"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}