e-Sys Electric Axle: Electrification Solution for Commercial Vehicles 2023-36-0350

With the increase in demand for energy sustainability projects over the last few years, the Brazilian commercial vehicle industry was guided to develop projects based on ESG policies. Aligned with this need, an initiative that ended up becoming a reality was the “e-Sys” electrification solution, by the company Suspensys. This solution includes a power source (battery), an e-powertrain (motors, inverters and drive axle) and an intelligent control system (VCU with embedded code and sensors). The main motivational drive was the hybridization of semi-trailers, in order to generate a reduction in fuel consumption in cargo transport in Brazil, in addition to the consequent reduction in the emission of particles into the environment and promoting the safety of the operation. It was also adopted, as a premise of the project, that the electrification system was totally independent of the truck’s electronic system (stand alone system), in order to facilitate the operation of the fleet owner. The solutions went through the four main phases of an automotive development: PoC, MVP, Fleetseeding (customer experimentation) and SoP. All of these were supported by various safety, functionality, performance and endurance tests, unrestricted for product validation in terms of robustness and, above all, safety. The regenerative brake system also proved to be one of the additional benefits within the product’s payback chain, given the reduced need for maintenance. During development, it was identified that the application of the electric axle would not be restricted to the hybridization of semi-trailers due to the synergy with other models of commercial vehicles, both in the helper/hybrid mode (in which the system acts as a support, helping the main system truck tractor), and in full electric mode (in which the system acts as the vehicle’s only tractor). In addition to representing the entry of Suspensys into the electromobility market, e-Sys also paved the way for the construction of the first Brazilian battery assembly plant with 100% Brazilian capital and know-how, within the Caxias do Sul manufacturing park.