Wheel Technologies for Battery-Electric Trucks
Leading the Charge in E-Mobility Solutions
As the automotive industry accelerates towards a sustainable future, Maxion Wheels stands at the forefront, driving innovation in wheel technology for battery-electric vehicles (BEVs). With a legacy of engineering excellence and a commitment to sustainability, Maxion Wheels is uniquely positioned to address the challenges and opportunities presented by the transition to e-mobility.
The Weight Challenge of Battery-Electric Trucks
Battery-electric trucks are significantly heavier than their conventional counterparts, primarily due to the weight of the battery packs, and thus can offer lower payload capacity. To address these potential payload disadvantages, the European Union is considering new legislation to increase the maximum weight of zero-emission commercial vehicles from 40 tons to 44 tons.
This additional 10% weight increase in vehicle mass places more complex physical demands on the wheels. Battery-electric trucks experience higher torque and acceleration, which can increase wear and tear on the wheels. Moreover, the front axle load can increase by up to 500 kg per wheel, necessitating robust and innovative wheel designs that require specialized expertise to handle these enhanced stresses.
Innovative Design and Materials
Maxion Wheels’ in-depth understanding of the wheel enables the company’s experts to tackle these challenges with a mix of experience and ingenuity.
“At Maxion Wheels, we are committed to leading the charge in e-mobility by developing lightweight wheel solutions that meet the unique demands of battery-electric trucks. Our latest designs not only enhance payload capacity but also ensure that our customers can transition to sustainable transport without compromising on performance or durability,” said Ralf Duning, Global Senior Commercial and Technical Advisor, Maxion Wheels.
By leveraging its vast production know-how and focusing on structural optimization, as well as the use of higher strength steel, Maxion Wheels has developed a new commercial vehicle steel wheel specifically designed for battery-electric trucks that offers a weight-neutral load increase of 250 kg.
The wheel’s distinctive leaf-shaped vent holes are not only a striking design feature but also the result of Maxion Wheels’ proprietary Lightweighting Process. This process integrates key performance parameters, advanced structural simulation tools and production know-how, making the fine-tuning of design, mechanical properties, and mass an integral part of the development and manufacturing.
The introduction of supercomputing at Maxion delivered a quantum leap in performance of the Lightweighting Process, scaling up the company’s topology optimization and simulation skills and processes. These investments have enabled company engineers to assess thousands of designs to identify the highest performing solutions. With an increased load capacity of 4,250 kg, these design enhancements not only improve the wheel’s structural integrity but also contribute to a lightweight design that supports increased payload capabilities.
Rigorous Testing and Performance
As a technical lead to the Association of European Wheel Manufacturers (EUWA), test partner to TÜV, the international voice on quality certification, and with Maxion Wheels’ own state-of-the art test equipment, the new wheels have undergone extensive testing to the highest OEM and EUWA standards. Initial fatigue strength tests have confirmed that the durability and performance of the new wheels is comparable to current generations, providing reliability and efficiency for customers.
Market Reception and Future Outlook
The market for battery-electric trucks is anticipated to grow steadily, though at a gradual pace due to current infrastructure challenges and higher upfront costs. However, with projections indicating a 25% penetration of zero-emission vehicles in the heavy and medium-duty truck sectors by 2030, coupled with a strong momentum in bus electrification driven by urban decarbonization initiatives, the outlook for battery-electric vehicles is increasingly optimistic.
Maxion Wheels is committed to supporting this transition with cutting-edge wheel solutions that enhance the efficiency and performance of battery-electric vehicles, including new wheel designs for different applications and load ranges.