Electric Semi-Truck Proven in Heavy-Duty Transport: A 94-Ton Road Train Case From Sweden
Electrification of heavy-duty transport is no longer limited to urban delivery or short regional routes. With advances in drivetrain technology, battery capacity, and trailer integration, electric semi-trucks are now capable of handling demanding heavy-load logistics—offering fleets lower emissions, higher payload efficiency, and predictable operational costs.
Here, we break down a real-world solution: a 94-ton electric road train operating in Sweden, demonstrating the feasibility and scalability of electric heavy-duty logistics.
System Overview: Electric Semi-Truck + Double Trailer Configuration
The solution employs:
- Electric semi-truck: Scania R 450E A6x4HB electric semi-truck
- Trailers: Two connected trailers using a dolly, forming a 33.5-meter road train
- Total weight: 94 tons
- Payload: 63.3 tons
- Cargo volume: 200 m³
Powertrain highlights:
- Maximum motor power: 450 kW (≈612 hp)
- Maximum motor torque: 3,500 Nm
- Battery system energy: 624 kWh
- Fast charging capability: 375 kW DC, fully recharged in ~1 hour
- Regenerative braking: up to 600 kW
This configuration enables daily trips of 150 km, with the electric semi-truck maintaining energy efficiency and reliability under heavy-duty operations.
Key Engineering Advantages
- Payload optimization: The high-capacity electric powertrain allows the combination to carry 36% more payload than standard diesel trucks, reducing trip frequency and improving fleet efficiency.
- Energy efficiency: Large battery system energy combined with high-power regenerative braking ensures effective energy recovery during deceleration, downhill operation, and stop-start driving.
- Scalable charging strategy: Integration with high-power DC chargers at terminal points supports predictable turnaround times, crucial for logistics operators managing tight schedules.
Real-World Application: Timber Logistics Case in Sweden
In Sweden, a 33.5-meter electric road train transports timber between Karlskoga and Skoghall, leveraging:
- Side-tipping trailers for efficient unloading of wood chips
- Double-trailer setup to maximize cargo volume and payload efficiency
- Predictable route operation, ideal for electric drivetrains
The system demonstrates that electric semi-trucks can handle high payloads (63.3 tons) and large cargo volumes (200 m³) while reducing CO₂ emissions by over 1,000 tons annually for a single fleet.
Expanding Applications
This electrification approach is applicable beyond timber transport. With predictable routes and heavy payload requirements, similar electric semi-truck solutions can be deployed for: highway side tippers, heavy-duty side tippers, mining side tippers, tankers, bowl tippers, belly dumpers, and specialized industrial trailers.
Key considerations for fleet integration include:
- E-powertrain and battery sizing for the payload and route
- Charging infrastructure placement along fixed routes
- Trailer design for optimized loading/unloading
- Regulatory compliance for road train length and weight
Takeaways for EV Builders and Trailer Manufacturers
Electric semi-trucks are no longer limited to short-haul or urban applications.
With the right system architecture and operational design, electrification is now technically and commercially viable for heavy-duty logistics.Application scenarios must be defined before electrifying the semi-truck and trailer system.
Duty cycles, payload profiles, road conditions, climate, and route predictability directly influence vehicle-level control strategies, energy management logic, and system calibration. Electrification should be driven by real operating conditions—not by generic platform assumptions.System integration is a prerequisite, not an afterthought.
The semi-truck, trailer, battery system, charging infrastructure, and control software must be engineered as a unified system to ensure stable performance under high-load operation.Payload efficiency gains translate into measurable operational value.
Higher usable payloads reduce trip frequency, lower cost per ton-kilometer, and improve fleet productivity—while simultaneously cutting emissions.Mature and reliable solutions matter in heavy-duty electrification.
For EV builders and trailer manufacturers, proven components, validated system architectures, and field-tested configurations are essential to minimize technical risk and ensure long-term operational reliability.
This case demonstrates that, when electrification is approached from a system-level, application-driven perspective, electric semi-trucks can become reliable and scalable alternatives to diesel in heavy-duty logistics—offering a realistic path forward for fleets and OEMs alike.
Our EV Solutions for Semi-Trailer Truck Electrification
At Brogen, we support pilot electrification projects for EV builders and trailer manufacturers by providing tailored e-powertrain solutions for heavy commercial vehicles.
Brogen Electric Powertrain Solutions for Semi-Trucks - Central Drive Traction Motor + Multi-Speed AMT
For electric semi-trucks, our e-powertrain portfolio includes a central drive motor combined with a multi-speed AMT transmission, designed to meet the torque and durability requirements of heavy-duty operations.
This architecture is well-suited to high-payload and variable-duty-cycle applications, offering robust traction performance while maintaining drivetrain efficiency across different operating conditions.
- Maximum motor power: up to 550 kW
- Maximum system output torque: over 24,000 N.m
- Learn more here: https://brogenevsolution.com/electric-motors-for-truck/
Brogen Electric Powertrain Solutions for Semi-Trucks - Electric Drive Axle
In addition, we offer more compact electric drive axle (e-axle) solutions, with multiple configurations available:
- Single-motor or dual-motor architectures
- Central drive or distributed drive layouts
These solutions are adaptable to a wide range of HCV applications. Depending on configuration, the maximum system output torque can exceed 50,000 N.m, enabling reliable performance under extreme load conditions.
- Learn more here: https://brogenevsolution.com/electric-axle-for-truck/
Brogen Electrified Trailer Solutions
For the trailer side, we also provide electrified trailer solutions based on our dual-motor electric axle technology. This approach enables the trailer to contribute to vehicle dynamics and energy efficiency actively.
Key benefits include:
Auxiliary Traction Support
Provides additional driving force to support the semi-truck during acceleration, hill climbing, and heavy-load operation, improving overall drivability and reducing peak load on the tractor powertrain.Intelligent Regenerative Braking
Electrically decouples regenerative braking from mechanical braking, allowing precise brake force control and maximizing energy recovery without compromising braking safety or stability.Reduced Energy Consumption of the Tractor
By sharing traction and braking loads, the electrified trailer helps lower energy demand on the semi-truck, extending effective driving range and improving overall system efficiency.Improved Stability Under Heavy Loads
Active torque control at the trailer axle enhances vehicle stability during low-speed maneuvering, uneven road conditions, and downhill operation.Modular and Scalable Integration
The electrified trailer system can be integrated into new platforms or pilot projects with minimal impact on existing vehicle architecture, making it suitable for phased electrification strategies.Optimized for Application-Specific Control Strategies
The system supports application-driven control and energy management strategies, allowing OEMs and EV builders to tailor performance based on real-world duty cycles and operating environments.- Learn more here: https://brogenevsolution.com/electrified-trailer-solution/
Contact Us
If you are exploring an EV system for your project, we welcome you to start a technical discussion with our team. You may contact us directly at contact@BrogenEVSolution.com or complete the form below.
Contact Us
Get in touch with us by sending us an email, using the Whatsapp number below, or filling in the form below. We usually reply within 2 business days.
Email: contact@brogenevsolution.com
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Whatsapp: +8619352173376
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