The road to decarbonisation for the commercial vehicle sector is proving to be a complex and challenging journey, with experts highlighting that a straightforward ‘combustion engine ban’ for lorries and other commercial vehicles is far more difficult to implement than for passenger cars.

Following the European Union’s strict CO2 fleet regulations for passenger vehicles, which effectively introduce a ban on combustion engines, stringent greenhouse gas limits are also being rolled out for commercial vehicles.

Experts at the International Vienna Motor Symposium stressed that the industry is racing to develop a wide array of solutions to match the huge diversity of vehicles on the road – from long-distance trucks and small delivery vans to construction and agricultural machinery.

Prof. Bernhard Geringer, Chairman of the International Vienna Motor Symposium, noted that the entire commercial vehicle industry is working on a wide range of solutions needed to match the diversity of vehicle types on the road in view of the developments expected in 2026.

The legislative pressure is intense. Tobias Stoll, a project manager at the Research Institute for Automotive Engineering and Vehicle Engines Stuttgart (FKFS), pointed out that EU legislation stipulates ‘a 45 percent reduction in CO2 emissions by 2030 compared to 2019,’ with manufacturers facing heavy financial penalties for non-compliance.

This has set the industry's course, with Frederik Zohm (pictured above), Chief Technology Officer at MAN Trucks & Bus, expecting ‘major transformations in the commercial vehicle sector by 2030.’

Egon Christ, Chief Strategist at transport and logistics service provider Mosolf, commented: ‘The course has been set.’

However, the existing transport model, especially for long-haul journeys, is heavily reliant on fossil fuels. A typical diesel lorry has a service life of 1.5 million kilometres, often covering up to 200,000 kilometres annually.

Ten years ago, EU forecasts anticipated a dominant role for hydrogen and a minor one for battery-electric trucks. The reality has turned out to be ‘exactly the opposite,’ according to Nils-Erik Meyer, a division manager at Akkodis Germany.

Today, there are only around 10 fuel-cell truck models in the EU, compared to over 40 battery-electric models.

While battery-electric vehicles are currently the most technologically advanced, their widespread use hinges on a massive overhaul of charging infrastructure.

Oliver Hrazdera, site manager at Akkodis Austria, calculated: “For trucks with an electric range of 500 kilometres, the EU needs 2,000 charging points with 650 or 1,000 kilowatts of charging power.”

Batteries, payload and hydrogen’s setbacks

Freight companies prioritise fast turnarounds, which necessitates rapid charging. Dorothea Liebig, a manager at Shell Global Solutions Germany, explained that the maximum charging capacity for trucks ‘is up to eight times higher than for cars.’ She also highlighted the alternative of battery swapping, particularly prevalent in China, where it is ‘fully automated and takes just seven minutes’ at the over 1,200 existing battery replacement stations for trucks.

For many journeys, electric trucks are already viable. Meyer from Akkodis calculated that with a mandatory driver break and recharging, a truck could cover ‘around 630 kilometres are possible in one shift. This covers 90 percent of all journeys.’

However, a key disadvantage of battery-electric lorries is the impact on payload, which is reduced by ‘three to six tonnes for the drive system, mainly due to the batteries,’ according to Meyer. By contrast, hydrogen fuel cells only reduce the payload by one tonne.

Despite this advantage, enthusiasm for fuel cells has cooled in Europe. Markus Heyn, Managing Director of Robert Bosch and Chairman of Bosch Mobility, reported that in Europe and the US, a major hurdle has been the substantial cooling requirements for fuel cells, which need ‘two to two and a half times more cooling surface area than diesel trucks,’.

According to Rolf Dobereiner, product line manager at AVL List. This increased requirement consumes up to 40 kilowatts, reducing driving performance and creating challenges for achieving the high-power outputs needed for heavy-duty haulage.

An unexpected dark horse has emerged: the hydrogen combustion engine. This technology offers compelling benefits, as it doesn't require the costly, high-purity hydrogen needed for fuel cells.

Christian Barba, Senior Manager at Daimler Truck, noted that it saves costs ‘as 80 percent of the parts of a diesel engine can be reused.’

Moreover, Anton Arnberger, Senior Product Manager at AVL List, reported that it ‘is the only zero-emission technology that does not require the use of rare earths.’

The hydrogen engine ‘could achieve the torque and power of a gas or diesel engine,’ said Lei Liu, a manager at Cummins in Beijing. Cummins is testing these vehicles in India, where they are seen as a main pillar for transport decarbonisation, given the lack of a comprehensive power grid required for electric trucks.

Developers are also looking at alternatives to gaseous hydrogen. The trend in Europe is moving towards liquid hydrogen, which allows for longer ranges and is cheaper to store.

Furthermore, Yuan Shen, Chief Developer at Zhejiang Geely Holding in China, proposed methanol as ‘the best carrier of hydrogen,’ as it is a liquid fuel that is easy and safer to store and transport.

Shipping, special vehicles and hybridisation

Decarbonisation is equally challenging on the high seas. Andreas Wimmer, a professor at Graz University of Technology, reported that engines for the 100,000 ocean-going vessels in service today have a life span of over 25 years and cost hundreds of millions of euros.

By 2050, these giants must also be CO2-free. While the combustion engine will remain, fossil heavy fuel oil must be replaced by ammonia (considered an ‘up-and-comer’), methanol or limited-quantity biofuel.

The special vehicle sector – such as construction and agricultural machinery – presents one of the toughest challenges. Stefan Loser, department head at MAN Truck & Bus, noted that a forage harvester would need ‘36 tonnes of batteries to run purely on electricity,’ which is impractical. For such machines, which are used intensively for short periods, hydrogen fuel cells or combustion engines running on synthetic fuels will be essential.

Finally, in the USA, where the decarbonisation of transport is ‘less aggressive than in Europe,’ according to Chris Bitsis, head of development at the Southwest Research Institute, hybridisation (the combination of combustion engines and electric drives) is seen as a key strategy to maintain everyday usability while significantly reducing consumption and emissions.

Summing up the current situation, Prof. Bernhard Geringer concluded that battery-electric drives in commercial vehicles are currently only realistic for distances of up to 500 km and with sufficient fast-charging options. He stressed that the special vehicle sector is particularly difficult, which is where ‘hydrogen fuel cell drives or combustion engines with synthetic fuels come into play.’

Comments (0)

ADD COMMENT

Link Copied!

Bengaluru-headquartered engineering R&D company L&T Technology Services (LTTS) has been certified at Caterpillar’s 2025 Supplier Excellence Recognition (SER) event. This marks the second consecutive recognition for LTTS following its initial certification in 2024.

The recertification highlights LTTS's delivery, quality standards and its relationship with Caterpillar in the Mobility segment.

As a strategic supplier, LTTS provides engineering services that support Caterpillar and its customer base. LTTS has worked on Caterpillar’s sustainability goals and has driven engineering innovation and operational performance.

Alind Saxena, Executive Director and President of Mobility and Tech at L&T Technology Services, said, “This recognition means a great deal to all of us at LTTS. Being SER-certified two years in a row is a testament not just to our team’s dedication, but also to the strength of our relationship with Caterpillar. We deeply appreciate Caterpillar’s support and the trust placed in us. Our pledge is to continue raising the bar, adding value, and delivering engineering excellence in everything we do.”

Caterpillar's recognition is awarded to suppliers who meet criteria in areas including quality assurance, timely delivery, innovation and alignment with the company’s values.

Comments (0)

ADD COMMENT

Link Copied!

Aptiv, a global technology firm, has announced its Gen 8 radar technology, designed to meet the demands of advanced driver-assistance systems (ADAS). The radars, powered by Aptiv’s antenna and silicon design, deliver the performance and resolution needed to support Artificial Intelligence (AI) and Machine Learning (ML)–driven ADAS functions.

The Gen 8 radars are intended to allow hands-free driving in complex city environments, providing perception at a lower cost. Both front-facing and corner radar units represent a step forward in how vehicles sense their surroundings, offering reliable performance across real-world conditions.

The same core technology also powers the new Aptiv PULSE Sensor, a solution that combines radar and camera data to improve perception around the vehicle. By integrating ultra short-range capability with a surround-view camera, PULSE is claimed to be able to replace up to four ultrasonic sensors, improving detection accuracy while reducing system complexity and cost for vehicle manufacturers.

Javed Khan, Executive Vice-President and President of Software, Advanced Safety and User Experience, Aptiv, said, “Aptiv pioneered radar technology in production vehicles more than two decades ago, and today, we’re once again setting the pace. Our Gen 8 Radars mark a major step forward in the journey toward intelligent, software-defined vehicles – delivering all-weather reliability, 4D perception and deep environmental awareness that enable global automakers to safely and cost-effectively scale to higher levels of automation.”

Backed by over 25 years of radar technology experience, Aptiv’s Gen 8 radars use proprietary software and hardware, introducing improvements in performance for a broader range of driving solutions across challenging weather and lighting. The radars enable new driving scenarios – such as Navigation on Autopilot (NOA) – in complex environments like city streets and car parks, due to an expanded field of view.

The key features of Aptiv’s Gen 8 radar technology include –

• Forward Radar: Offers long-range detection beyond 300 metres with fine 4D angular resolution, allowing improved classification of static objects. This system delivers a 30 percent performance increase and doubles the vertical field of view compared to its predecessor.
• Dual-Mode Corner Radar: Improves the range performance of the previous generation by increasing the vertical field of view’s (FOV) resolution, providing capability in close-range, low-speed scenarios such as frontal automatic emergency braking (AEB) and automated parking. Compared to the prior generation, horizontal discrimination improved by 25 percent and vertical discrimination is now possible.

The Gen 8 radars aim to deliver detection, precision and adaptability. Aptiv claims it offers scalable solutions, including a large increase in object detection count and superior accuracy for target detection and tracking, even in high dynamic range environments. It also supports AI-powered systems by delivering high-quality sensor data to machine learning models.

Comments (0)

ADD COMMENT

Link Copied!

United States-based Edge Energy, a developer of patent-pending energy conversion technology for electric vehicle fast charging, has announced a strategic investment from Germany-based PRETTL Mechatronics & Actuators (PMA), a leading mechatronics solution supplier for the automotive, electronics and energy sectors.

The funding round includes an equity investment and working capital. This partnership will support Edge Energy’s expansion of access to EV charging and utilise PMA’s manufacturing and electronics capabilities.

Edge Energy’s EdgeEV Power Source is claimed to allow fast EV charging without expensive three-phase power upgrades, offering deployment up to six times faster than traditional methods. The technology allows businesses and fleet operators to install DC Fast Chargers in various locations, supporting EV uptake.

PMA’s U.S. subsidiaries provide capabilities in coil winding, encapsulation and automated assembly, serving industries like automotive and energy.

Shaun Shuler, CEO, of Edge Energy, said, “We’re thrilled to partner with PMA, whose electronic and manufacturing expertise aligns perfectly with our vision for accessible EV charging.”

Johannes Prettl, CEO, PMA Group, said, “Edge Energy’s innovative EV charging solutions complement PMA’s commitment to sustainable technologies. We are excited to partner with Edge Energy on their next stage of growth.”

The investment combines Edge Energy’s technology with PMA’s electronics and manufacturing capabilities, aiming for growth for Edge Energy.

Comments (0)

ADD COMMENT

Link Copied!

Tata Technologies has announced a partnership with Synopsys, a provider of engineering solutions, to accelerate the shift towards Software-Defined Mobility (SDV). The collaboration aims to accelerate the development, verification and validation of automotive electronics systems, helping Original Equipment Manufacturers address the complexity of SDVs.

The collaboration will combine Tata Technologies’ expertise in vehicle engineering with Synopsys’ virtualisation solutions to enable the deployment of electronics digital twins (eDTs).

The companies have already worked with a leading European luxury OEM in a pilot engagement, delivering a blueprint to transition the manufacturer's existing electrical/electronic (E/E) architecture to a next-generation software-defined design. Pilot programmes with other major OEMs are also underway across North America, Europe and India.

The joint effort will focus on major SDV domains, including ADAS, powertrain, chassis, infotainment and electrification. Key areas of focus include:

• Shift Left Enablement: Developing virtual prototypes and simulation models for early software bring-up.
• Analysis: Using Synopsys tools for performance, power, safety, and reliability analysis for faster ECU development cycles.
• Verification: Providing embedded systems and software verification and validation services aligned with ISO 26262 and ASPICE standards.

Sriram Lakshminarayanan, Chief Technology Officer, Tata Technologies, said, “The digital shift is redefining the future of mobility, and our partnership with Synopsys is a purposeful step towards realising a future led by software-defined innovations. As OEMs move to new ways of working, there is a growing demand for engineering and digital services. Together, we are empowering OEMs to deliver safer, smarter, and more sustainable vehicles that enhance the human experience and accelerate the industry’s transition to a software-defined future.”

Tom De Schutter, Senior Vice-President, Product Management & Markets Group at Synopsys, said, "The complexity of SDV systems requires a new level of collaboration across the automotive ecosystem. By bringing together our world-class digital twin, verification, and IP platforms with Tata Technologies’ engineering expertise and global delivery, we are enabling OEMs to accelerate development, validation and delivery of complex software- and AI-defined vehicles. The collaboration is a great example of how the automotive ecosystem is coming together to accelerate innovation while reducing risk and time to market in a dynamic mobility landscape.”

Comments (0)

ADD COMMENT

Link Copied!