Technical Paper
Vehicle Control Development - Converting a Medium Duty Commercial Truck into a Battery Electric Vehicle
2024-04-09
2024-01-2047
The transition towards electrification in commercial vehicles is getting more attention in recent years. This technical paper details the conversion of a production medium duty class-5 commercial truck, originally equipped with a gasoline engine and 10-speed automatic transmission, into a battery electric vehicle (BEV). The conversion process involved the removal of the internal combustion engine, transmission, and differential unit, followed by the integration of an ePropulsion system housing a newly developed dual-motor eBeam axle that propels the rear wheels. Complementary additions encompass components such as an 800V/99 kWh battery pack, advanced SiC inverters, an 800V HVAC system, and a DC fast charging system. Central to this study is the control system governing the converted vehicle, prioritizing drivability, NVH suppression, and energy optimization. Evident improvements in responsiveness and reduced noise emission underscore the efficacy of the BEV's design.