Automotive

Tevva boosts regenerative braking efficiency for medium-duty truck by 4x

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Tevva has completed development of its regenerative braking system with help from ZF
Tevva
Tevva has completed development of its regenerative braking system with help from ZF
Tevva
Tevva will use the EBS regenerative braking system for its 7.5-t medium-duty commercial truck
Tevva
Tevva and ZF worked together to integrate ZF's electronic brake system with Tevva's regenerative hardware
Tevva
Diagram of system components
Tevva
The completed regenerative system is designed to improve energy recuperation, cut wear and tear on components, increase braking stability and more
Tevva
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Determined to lead the charge toward zero-emissions freight and urban logistics, British electric truck maker Tevva has been working to ease the burden of carbon reductions on fleet operators. In January, it began production of its battery-powered medium-duty electric truck, for which it also plans to offer a hydrogen fuel cell range extender. For now, it's extending range a simpler way, improving its regenerative braking system so that it's four times more efficient than it was previously.

Tevva worked with German Tier 1 automotive supplier ZF to greatly improve upon the regenerative braking system that's a cornerstone of its TEV75 medium-duty electric truck. The companies adapted ZF's electronic braking system (EBS) for use with Tevva's combined regen and compressed-air braking system. The EBS electronically splits the driver's brake input into a blend of conventional air-powered friction braking and electric-motor regen braking that delivers improved response and safety, more balanced braking, and reduced wear and tear on components.

Diagram of system components
Tevva

"When the brake pedal is pushed, most of the 'braking' is handled by regen, meaning that the drive system slows the vehicle down," explained Tevva's lead drive and brake systems engineer Uzair Jilani. "The conventional braking system is still needed to bring the truck to a complete stop, but this double layer of safety is an excellent aid to more efficient driving. It also means that the hardware undergoes less strain to extend the braking system's life in the long run."

Now that most of the braking is under the domain of regeneration, the system is able to safely output up to 180 kW back to the battery. Prior to the addition of the ZF EBS hardware, it was only able to safely regenerate at rates up to 40 kW, via the passive regeneration from the air braking system. This improvement promises to deliver more power back to the battery during driving, thereby actively increasing range per charge.

As for exactly how much mileage the system adds to the total range, Tevva doesn't provide an estimate. It advertises a 140-mile (227-km) total range for the TEV75 truck, which comes equipped with a 105-kWh battery pack.

Tevva will use the EBS regenerative braking system for its 7.5-t medium-duty commercial truck
Tevva

Tevva engineers worked carefully to make the braking system compliant with ZF's stringent approval criteria. As part of the process, it tuned its vehicle control unit (VCU) for better integration and compatibility with the ZF EBS.

Tevva's 140-mile all-electric truck is in production now, and the company will next add the 7.5-t hydrogen-electric model, more than doubling the range of the BEV version for up to 354 miles (570 km).

Sources: Tevva and ZF

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2 comments
TechGazer
How much energy can be returned by regenerative braking, at least for big vehicles in urban stop-and-go traffic? Adding a variable ratio transmission to the drive might help recover energy (power output of electric generators depends on rpm). As the vehicle slows, the ratio can switch higher to maintain regeneration output, and also braking force. Theoretically more efficient, but it boils down to cost/benefit. For urban trucks, maybe it would be worthwhile.
jerryd
Last time I checked catching up with everyone else in regen, is not an advance, a sign of how backward they are. Regen is helpful, but not as much as people think.
In fact 1 pedal driving wastes energy as constantly slowing, speeding up needlessly vs just coasting and only have regen on the first part of the brake pedal.