Event – Network Meeting for the Overhead Line Projects
On December 11th, our team co-organized the “Networking Meeting for Overhead Line Projects” in Frankfurt, bringing together over 100 participants to discuss the future of overhead line technology. Our project leader Gordon Witham presented our project and showcased our retrofitted battery-electric truck “Willi”. The event featured workshops on the field trial results, a plenary session on introducing overhead line technology, and an expert panel with Arjan van Vliet (Ministerie van Infrastructuur en Waterstaat), Axel Hausen (Netze BW GmbH) and Jörg Salomon (Deutsche Post DHL Group), discussing the “Pathways for Introducing Overhead Line Technology“. After the event, we continued our field trials on the A5 throughout the remaining week before going into our well deserved Christmas break.
Die Autobahn GmbH des Bundes
FuE-Zentrum FH Kiel GmbH
Clemens Schmidt
Event – Network Meeting for the Overhead Line Projects
On December 11th, our team co-organized the “Networking Meeting for Overhead Line Projects” in Frankfurt, bringing together over 100 participants to discuss the future of overhead line technology. Our project leader Gordon Witham presented our project and showcased our retrofitted battery-electric truck “Willi”. The event featured workshops on the field trial results, a plenary session on introducing overhead line technology, and an expert panel with Arjan van Vliet (Ministerie van Infrastructuur en Waterstaat), Axel Hausen (Netze BW GmbH) and Jörg Salomon (Deutsche Post DHL Group), discussing the “Pathways for Introducing Overhead Line Technology“. After the event, we continued our field trials on the A5 throughout the remaining week before going into our well deserved Christmas break.
First test drive at ELISA
The first drives on the ELISA overhead line test track have been completed. Lotte Wagner-Douglas and Gordon Witham have covered the first kilometres under the overhead line on the A5 between Frankfurt and Darmstadt. In addition to collecting measurement data in public road traffic, the aim was also to carry out a pre-test for the upcoming proband study, which is planned as part of the project to evaluate user acceptance. The first test drive was rounded off by a visit from representatives of Autobahn GmbH, who wanted to familiarise themselves with the vehicle and accompanied us on a tour.
‘Willi’ fully wrapped and ready for further test drives
Our ‘Willi’ now shines in a new design! Our vehicle designers have created a customised wrap that is based on the project design and visually highlights the innovative technology behind the vehicle.
With the vehicle wrapping, the conversion of ‘Willi’ is now complete and the vehicle is ready for the next test phase. The next stop: the ELISA test track between Frankfurt and Darmstadt, where ‘Willi’ will demonstrate its performance under real-life driving conditions.
Joint test drives by BEE and FESH
Following the night-time test drives, Hendrik Vorjans and Gordon Witham took part in a joint research drive for the FESH project with ‘Maja’ and ‘Willi’. In addition to the two retrofitted battery-electric DAF trucks, two overhead line hybrid trucks from the freight company Bode and a battery-electric overhead line truck from Deutsche Post / DHL, manufactured by Scania, also took part. The test drives went off smoothly in wintry conditions.
The five overhead line trucks, which were connected to the overhead line at the same time during the research trip, were used to collect additional data for evaluating the battery storage system from the PowerCharger project.
A short video of the joint research trip can be found here:
Video from FESH
Final commissioning in the Schleswig-Holstein field trial
Following the successful registration of both vehicles, we carried out some final tests on the Schleswig-Holstein field trial (FESH) test track between Lübeck and Hamburg. In order not to endanger regular traffic, the tests took place at night in a partially closed section of the A1 motorway. All tests went smoothly, so that ‘Willi’ was also given the final go-ahead for road use.
Our second prototype is finished and registered
‘Willi’ is the second battery-electric truck to be successfully retrofitted with a pantograph system. It differs from ‘Maja’ mainly in its galvanically isolated DC/DC converter, which enables a higher charging capacity, as well as an optimised design of the pantograph tower.
In addition, ‘Maja’ and ‘Willi’ have received their road licence today and are ready for test drives in real road traffic. This makes them the first overhead line trucks with road approval without the need for a special permit, as both vehicles and the retrofit concept meet all the requirements for obtaining an operating licence.
‘Maja’ was tested in the EMC laboratory
Our first retrofitted battery–electric truck ‘Maja’ has reached another milestone after the initial presentation and demonstration: the electromagnetic compatibility (EMC) was successfully tested in accordance with the ECE–R10 standard. The tests took place this week at EMC Test NRW GmbH in Dortmund.
Our colleagues Clemens Schmidt and Thilo Londong accompanied the tests on site and supported the laboratory team, as even for the EMC experts a truck with a pantograph is not an everyday occurrence. These tests are an important step in the homologation process and bring our vehicle closer to final road approval.
Demonstration of the first battery-electric truck with retrofitted pantograph system
On August 20th 2024, we presented “Maja“, the world‘s first battery–electric truck with a retrofitted pantograph system, on the Siemens eHighway test track in Groß Dölln. Project participants from the associated partners DAF Trucks N.V. and Siemens as well as representatives of the project administrator VDI/VDE Innovation + Technik GmbH were able to inspect the first prototype of our BEE project and experience it during a demonstration drive on the test track under the overhead catenary line.
Following the successful commissioning and acceptance of the overall system and the first test drives on the eHighway test track, the next step will be to subject the first prototype to the necessary certification tests to obtain road approval. Comprehensive testing within the German overhead catenary line field trials is then planned in order to assess the system’s suitability for practical use in real road traffic.
BEE project was presented on flotte.de
The BEE project was presented in the flotte.de news blog. The retrofit concept for the pantograph system, the planned real-world testing and the current user study are covered.
(The article is in German language.)
Event – Decarbonisation of heavy road freight transport: Catenary technology as a building block for transport transformation
On July 1st, the event “Decarbonisation of heavy road freight transport: Catenary technology as a building block for transport transformation” was hosted in Berlin by the Ministry of Energy Transition, Climate Protection, Environment and Nature and the Ministry of Economics, Transport, Labour, Technology and Tourism of the State of Schleswig-Holstein. Our project manager Gordon Witham attended the event to catch up on the latest research results from the “eHighway field trial on the A1 motorway in Schleswig-Holstein (FESH)” and to discuss the future prospects of overhead line technology in the context of the energy and transport transition.
BEE at the test and driving event for trucks and commercial vehicles in Aldenhoven
Maren Klatt and Gordon Witham attended the NRW.Energy4Climate test and driving event for trucks and commercial vehicles at the Aldenhoven Testing Center on June 25th to present the BEE project. The two were not only able to gain an overview of current vehicles with alternative drive systems from various vehicle manufacturers, but also acquire participants for the current user study on truck purchasing decisions. This is aimed at individuals from logistics companies who are involved in purchasing decisions for trucks, is anonymous and takes approx. 5 minutes.
(The survey is in German language.)
Nutzerstudie zu Lkw-Kaufentscheidungen online
Seit heute ist die im Projekt entwickelte Nutzerstudie zu Kaufentscheidungen bei Lkw online. Hierfür werden Personen aus Logistikunternehmen gesucht, welche an Kaufentscheidungen für Lkw beteiligt sind. Die Ergebnisse der Umfrage fließen in die psychologische Begleitforschung des Projekts ein, welche ein wichtiger Baustein der Technologiebewertung darstellt. Die Umfrage ist anonym und dauert ca. 5 Minuten.
Umfrage
Pantograph retrofit system concept completed
Following the successful construction of the mechanical mock-up on the diesel truck, the concept phase of the pantograph retrofit system for the first battery-electric prototype has now been completed. Based on the acquired results, further material and weight savings were made and thermal management and power electronics were optimised depending on the market availability of components. The next step is the procurement of the individual parts and production of the pantograph tower.
Our battery-electric trucks have been produced
Great news just before the end of the year: Our two battery-electric DAF XDs have been produced and were handed over to our colleagues Roland Uerlich and Gordon Witham at the new “Electric Truck Assembly” of DAF Trucks in Eindhoven. The vehicles will remain with the manufacturer for some subsequent modifications, who will prepare them for road approval together with a body builder. The vehicles will then be delivered to Aachen in the new year, where we are eagerly awaiting to start the further integration of the pantograph system and various measurement equipment for the subsequent field tests.
Preparations are of course continuing in the background. Based on the results of the previous LiVe and LiVePLuS projects, the components of the pantograph system are being further optimised and adapted to the new vehicle type. In addition, initial test drives are being carried out with the diesel truck which has already been delivered in order to prepare the measurement equipment and methods for data evaluation in the best possible way for use in the battery-electric vehicles with and without overhead line connection.
Mechanical mockup successfully assembled
This week, we reached an important milestone at the Institute for Automotive Engineering (ika): We successfully manufactured and assembled the first prototype of the mechanical substructure of our pantograph system. In collaboration with the Chair of Production Engineering of E-Mobility Components (PEM), we were able to test the prototype on an identical diesel truck from the vehicle manufacturer DAF. We were able to successfully test the mechanical integration and gain important insights for further development. The substructure consists of various modules, including the “frame adapter”, which has a modular design and can therefore be used for other vehicle types and frame geometries. This flexibility opens up a wide range of possibilities for retrofitting other trucks in the future.
Finally, the pantograph system was test-mounted on the mechanical substructure to ensure the stability and precision fit of all components. The electrical and communication integration of the system is to be implemented in the battery-electric trucks later on. The concept successfully passed this first mechanical test.
The first vehicle has arrived
Our first vehicle, a DAF XD FAN, has been delivered.
As this one is still conventionally diesel-powered, it will serve as a placeholder for the construction and mechanical integration of the pantograph system. We are expecting two battery-electric trucks later this year for the full integration. Afterwards, the diesel truck will be used as a reference vehicle during test drives and measurements.
Pantographs have arrived
The pantographs from SIEMENS Mobility have arrived. Both electric trucks will be equipped with a pantograph each in order to be able to drive on the overhead line. Now it’s time to continue with the design and construction of the frame structures for the pantographs and the associated peripherals as well as measurement equipment.
DAF on board as an associated partner
We have been able to win the Dutch truck manufacturer DAF as an associated partner for the provision of vehicle platforms and development support under subcontract. DAF is supplying two battery-electric trucks of the new generation XD, which will be extended to use the overhead line system. In addition, DAF is providing a diesel-powered reference vehicle to enable an extended technology comparison based on real vehicles and data.
Project launch BEV Goes eHighway
To kick off the BEV Goes eHighway project, the project participants from the Institute for Automotive Engineering (ika) and the Chair of Production Engineering of E-Mobility Components (PEM) at RWTH Aachen University met for a first joint meeting to discuss the planned project content. In particular, the seven work packages (WP) into which the project is divided were discussed.
In addition to coordinating the content, the agenda also included getting to know each other. The participants were able to come together directly within their work packages. At the end of the project kick-off, the consortium took a photo together in front of the ika simulator building.
Presentation of the “BEV goes eHighway” project
The “BEV Goes eHighway – BEE” project was launched in January 2022. The aim of the project is to further develop overhead line technology for heavy-duty road transport in order to establish fully electric drive alternatives for this sector in the long term.
The “BEE” project focuses on the construction of a catenary truck, testing within dedicated test fields as well as in real traffic, the preparation of user studies on customer acceptance and the determination of potential user groups, technology and potential analyses and an analysis of the essential vehicle interfaces with the final development of a standard proposal.
Within the project, the integration of overhead line technology on the basis of two battery-electric series-production trucks is being investigated and evaluated. The focus is on the viewpoint of the vehicle manufacturer, for whom the duration of the conversion phase of the series vehicle is particularly relevant. However, the vehicle manufacturer cannot currently use any set of standards as a guide to simplify the installation of the pantograph system. During the conversion phase, possible interfaces for a later standardisation of the system will be identified in cooperation with
the pantograph system manufacturers. This will simplify the conversion process in the future and thus create the basis for higher market penetration. Within the project, the research vehicles enable a direct technology comparison of a pure BEV truck and a catenary BEV truck and thus offer the possibility to evaluate the CO2 avoidance potential based on real driving data. The real driving data are determined by field tests.
Another outstanding feature of this project, in addition to the direct comparison of vehicles with and without overhead contact line, is the execution of extensive test drives on the premises of several test facilities in Germany. This will allow the technology to be evaluated on a route-specific basis, thus demonstrating its potential for application on public roads. The expected high volume of recorded data provides a meaningful basis for the technology assessment. On this basis, further studies will then be conducted on, among other things, the necessary battery capacity, vehicle range and payload.