HANNOVER, Germany—As trucks become more fuel-efficient, trailers are emerging as a critical technology area for further carbon emission reductions to meet transition timelines in Europe and the U.S., as global vehicle supplier ZF and several European trailer manufacturers explained at IAA Transportation 2024 here.
Under the new brand name TrailTrax, ZF's electric trailer concept integrates its in-house developed 210 kW AxTrax 2 e-Axle, trailer EBS, and battery system box into a trailer. Leading trailer manufacturers, including Kässbohrer and Krone, as well as trailer running gear and axle supplier BPW, are adopting ZF’s TrailTrax technologies.
See also: Connected trailers: Driving fleets into the future
ZF’s TrailTrax system provides driving propulsion as well as brake energy recuperation, generating up to 16% percent in energy and CO2 savings when combined with an ICE-powered truck. The system can also reduce CO2 emissions by up to 40% with plug-in charging.
Integral to the system is ZF’s electrified axle, the AxTrax 2, from ZF´s eDrive platform. Integrating it into a trailer running gear in combination with other associated system components effectively converts an ICE truck-trailer combination into a hybrid while extending the range of an electric vehicle.
“TrailTrax technologies offer significant potential to reduce operational costs and CO2 emissions in road freight transportation. Energy losses, including brake friction, air drag, and rolling resistance, are major causes of fuel inefficiency, but with our TrailTrax concept, we can make a big difference,” said Bernd Meurer, who is responsible for the TrailTrax program at ZF. “Successfully managing this transformative technology will require the combined efforts of all industry players. We are pleased to see our technologies are gaining traction among leading trailer manufacturers as well as fleet operators across the globe, who recognize the potential that TrailTrax can bring towards achieving sustainability goals.”
Proof of concept
ZF is collaborating closely with leading trailer manufacturer Kässbohrer to develop its electrified trailer solution. Kässbohrer’s electrified curtainsider, which features the system integration of TrailTrax, was featured prominently in the trailer OEM’s display area here.
“We highlight the importance of a wide ecosystem of innovation and partnerships to advance the trailer industry towards sustainability,” Kässbohrer Executive Board Member İffet Turken said. “We are proud to collaborate with ZF in the safe and efficient integration of their electrified axle, EBS systems, and battery pack into our trailers.
“Our prototyping is carried out at our state-of-the-art European R&D center with the goal to present customers an electrified trailer that both delivers on operational ease and efficiency and can be seamlessly integrated into their regular business operations while helping to contribute to CO2 reductions.”
Field tests of Kässbohrer trailers are expected to commence across Europe in 2025 under the EU-funded ZEFES (Zero Emissions Flexible Vehicle Platforms with Modular Powertrains Serving the Haul Freight Eco System) project.
Trailer manufacturer Krone has also featured its solution, highlighting the growing interest in ZF’s TrailTrax technologies. ZF’s outdoor booth featured a Krone reefer trailer with the TrailTrax system installed. The electrified Krone trailer, capable of reducing CO2 emissions by up to 40%, demonstrates the potential efficiency gains achievable with ZF TrailTrax technologies.
"At Krone, we believe in the importance of electrification in the context of the transformation of the transport sector and work with our industry partners to harness the potential of electrified trailers," said Markus Stegen, managing director of product management and new markets at Krone Trailer.
Trailer axle and suspension manufacturer BPW recognized the opportunity to work with ZF on the TrailTrax system.
“Every trailer needs a running gear, suspension, and braking technology that can be trusted,” Markus Schell, BPW managing partner, said. “With our axles for 7.5t trucks and the generator axles for reefers, we already have a lot of experience regarding the integration of electric drives. It therefore makes perfect sense that ZF, with expertise in drivelines, cooperates with BPW to offer a robust and highly engineered running gear solution with the AxTrax 2 axle for recuperation and traction support for semitrailers that can be easily assembled by trailer builders and is fully trusted by the fleets.”
