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  • Mojde khazenirazavi

Challenges in the Electrification of Commercial Vehicles

Updated: Apr 23

Electric Innovation: A Glimpse into History to Present

Electric Innovation: A Glimpse into History to Present


The electrification of commercial vehicles represents a critical frontier in the quest to reduce carbon emissions and combat climate change. Despite the historical milestone set by the Walker Motor Company in 1906, with the launch of the first fully electric truck (driven by a rear axle motor and able to cover 80 Kms in a single charge with a top speed of up to 20 Kmph), the road to electrifying the commercial vehicle sector has been slow and fraught with challenges. As of 2024, a staggering 96.4% of trucks on the road still rely on diesel, highlighting the steep path ahead for electric trucks to gain substantial market share [1]. This article delves into the multifaceted challenges faced by companies in the development and production of electric vehicles (EVs) and outlines the efforts being made to surmount these obstacles.

1.      Design Challenges

The transition from internal combustion engine (ICE) vehicles to EVs fundamentally alters the vehicle's drivetrain. While ICE vehicles comprise an engine, clutch, transmission, and driveshaft, EVs replace these components with a battery, inverter, and motor. The challenge lies not only in designing these components to be as reliable as their ICE counterparts but also in innovating to enhance their efficiency and effectiveness. Decades of research have led to significant advancements, yet the quest for the perfect EV drivetrain continues.

2.      Technical Hurdles

At the heart of electric vehicles lie the battery and inverter technologies, both of which present significant challenges. Selecting the appropriate battery type and developing an efficient inverter to integrate seamlessly into the drivetrain necessitates extensive testing and fine-tuning. These components are pivotal in ensuring the vehicle's performance, range, and overall reliability. Some issues that may occur during the operation of the vehicles are:

·       Vibration loads

·       Corrosion

·       Electrics (for example shield and common mode currents)

3.      Sourcing and Component Handling

Lithium-ion (Li-ion) batteries are currently the most viable option for electric vehicles due to their reliability, affordability, and adaptability. However, this brings forth two major challenges: the mining of lithium and the handling of batteries during procurement and manufacturing. Furthermore, the industry has faced a notable chip shortage, impacting the availability of essential electronic components like the Silicon chips, which is crucial for vehicle control systems.

4.      Safety Concerns

Ensuring safety during vehicle operation is paramount. Challenges such as managing vibration, mitigating corrosion, and ensuring the durability of electric components under various operational stresses are significant. These issues require innovative solutions to guarantee that electric trucks are as safe as their ICE counterparts, if not safer.

5.      Technology Standardization

The lack of standardization, especially concerning charging infrastructure and battery technology, poses a considerable barrier to the widespread adoption of electric commercial vehicles. Developing universal standards could facilitate a more seamless integration of EVs into existing transportation networks and encourage broader acceptance among fleet operators.

6.      Disposal and Recycling

The question of how to dispose of and recycle electric powertrains at the end of their life cycle is yet another challenge. While recycling technologies evolving, the costs associated with battery recycling are often incorporated into the vehicle's purchase price, influencing market competitiveness.

7.      Manufacturing Costs

Establishing manufacturing facilities for electric vehicles requires significant investment. The costs associated with setting up production lines equipped to handle EV-specific components and technologies can be prohibitive, especially for smaller manufacturers or new entrants to the market.

Despite these challenges, the industry is making strides toward overcoming these hurdles. Innovations in battery technology are extending vehicle ranges, and advances in power electronics are improving efficiency and reliability. Companies are also exploring sustainable sourcing methods for lithium and other critical materials, reducing the environmental impact of EV production.

To address safety concerns, manufacturers are investing in rigorous testing and quality control measures, ensuring that electric trucks meet or exceed the safety standards set for ICE vehicles. Efforts to standardize charging infrastructure and battery technology are underway, spearheaded by industry consortia and regulatory bodies working towards global standards.

As for disposal and recycling, advancements in battery technology are not only extending the life span of EV batteries but also making them more recyclable. Companies are developing more efficient and environmentally friendly recycling processes, and some are exploring the possibility of repurposing used EV batteries for stationary energy storage applications.

The high initial costs associated with manufacturing electric trucks are gradually being offset by technological advancements and economies of scale. As production volumes increase and the technology matures, the cost of electric vehicles is expected to decrease, making them more competitive with traditional ICE vehicles.

In conclusion, while the electrification of commercial vehicles presents a host of challenges, the industry's relentless pursuit of innovation and improvement signals a promising future. With continued investment in research and development, collaboration among stakeholders, and supportive policies from governments worldwide, the widespread adoption of electric commercial vehicles is within reach. The journey from the first electric truck to a future dominated by electric transport may be long, but the destination is becoming increasingly clear.


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