E-mission accomplished

One of the defining trends in the current era of global transport is e-mobility. SAF-Holland joined the electrification revolution, as it has been called, early on officially launching its first electrified axle, the TRAKr in 2018. The company wasted little time bringing the e-axle to our shores, with Australia the first market outside of Europe to receive the TRAKr.

New technology in the market can be daunting. Especially when its immediate value is largely unknown. Not so for Woolworths logistics division, Primary Connect, one of the first fleets to trial SAF-Holland’s TRAKr in 2022. The fleet liked what it saw. That initial evaluation was successful enough for the fleet to upscale its adoption of the technology rolling out e-axles across another 20 refrigerated trailers.

The recuperative electrified axle uses a high-voltage generator module for electric power regeneration to lower the emissions and fuel consumption of the overall vehicle. SAF-Holland Product, Engineering and Technical Manager, Nemanja Miletic, was in Germany working for the parent company during the very genesis of the project.

“The benefits are many,” he says. “A reduction in diesel aggregate to run the cooling unit on a refrigeration trailer or anywhere else where energy is needed in other applications to power equipment can be done with electrics.”

While having cooling units run on electricity is nothing new, as the trailer works independently from the truck, any trailer with the TRAKr e-axle can be connected to any truck to enable said benefit.

Reducing the diesel aggregate component also helps mitigate against noise levels which are prohibitive in making deliveries, especially at night, to supermarkets.

“More and more countries around the world have issues with noise levels emitted by commercial vehicles,” Nemanja says. “By removing those high noise levels, it enables increases in productivity because now you can do night shifts as the unit is no longer noisy but silent.”

Even in the medium-term the advantages are palpable in light of the legislation of restrictive zones where commercial vehicles must be classified as zero-emission to enter and operate. Some cities in Europe won’t allow refrigerated vehicles to enter based on the noise levels created by diesel aggregate. In this way an e-axle like the SAF TRAKr saves on fuel consumption while also improving a vehicle’s carbon footprint.

“Nowadays, for supermarket deliveries, it is more likely the truck will have a Euro 6 rating to make it as clean as possible on a legacy internal combustion engine, and yet the ‘dirtiest’ diesel aggregate can be running the cooling unit, so by actually removing that diesel aggregate we overcame this absurd situation and operators can be that much cleaner,” Nemanja says.

It’s important to dispel a misconception. The SAF TRAKr does not produce electricity through any process of regenerative braking. Rather, it works like a Dynamo in that it begins charging when the wheels start spinning hence it facilitates the reincorporation of energy.

“You can call it regeneration if you’re going downhill but it’s actually not related to braking,” Nemanja notes. “It’s connected to EBS, so under the speeds of 30km/h and even in emergency braking situations it will disconnect itself, so it doesn’t interfere with the dynamics of the vehicle and EBS.”

Tests conducted by SAF-Holland in Europe have validated the fuel savings and, by inference, lower operational overheads, its e-axle can deliver by replacing the consumption of diesel aggregate on the trailers.

“It’s approximately 2.2 litres of diesel per 100 kilometres saved,” Nemanja says. “That’s an important data point given the cost of fuel.”

As it has many more axles on road in Europe than it does here at present, it’s a point of pride for the team at SAF-Holland that the Australian market was prioritised for the TRAKr’s global rollout.

“New technology is expensive and a leap into the unknown,” Nemanja says. “We are very grateful for the courage and trust customers have shown our product and brand by coming on a journey with us — the journey of electrification.”

A second e-axle has also been part of trials for Martin Brower on a refrigerated combination used on the far-reaching McDonald’s supply chain.

But the ambitions of the project don’t begin and end with just the cold carrier segment.

“We see the future applications and use of these axles not just in refrigeration transport but also on bulk tankers, walking floors, lift gates, anything where you can use electricity to power your accessories,” Nemanja says.

Though the SAF TRAKr is still specified for wide single tyres with a 120mm offset, which is the standard disc brake 10-stud 335PCD option most prevalent in European transport, Nemanja confirms SAF-Holland is presently working on a project to develop a hub for Australian standard spec which is ten studs 285PCD dual tyres that would create opportunities for these other aforementioned applications.

Lowering CO2 emissions also means the SAF-TRAKr conforms to the latest Australian legislation for emissions. Just last year it was recognised by the HVIA with its annual Innovation Award.

Because it doesn’t have propulsion the SAF TRAKr can be installed like any other axle. Maintenance work on the axle is simple and cost-efficient as the drive unit does not have to be removed when uninstalling the wheel ends and wheels. The spare parts supply is also uncomplicated due to SAF TRAKr’s wear parts (brake pads, brake rotors and wheel bearings) being identical to the components for the non-driven SAF-Holland axles. This makes the spare parts supply easier and more reliable. Workshop technicians, however, may be required to do some additional training while working with high voltages.

“Currently it is the only electric trailer axle in Australia,” Nemanja says. “It’s great to see the implementation of an innovative idea into the local market.”