Trailer Dynamics, based in Eschweiler, North Rhine-Westphalia, has developed a comprehensive and unique solution to reduce diesel consumption in long-distance transport or significantly increase the range of battery-electric tractors (BEVs).
The core of the solution is an additional trailer-mounted electric drive system that supports the tractor’s drive.
“The centre axle is electrified using two powerful electric motors—each with 345 kW of power. The energy comes from a traction battery located where the pallet box used to be,” explains Michael W. Nimtsch, Managing Director at Trailer Dynamics.
The system is controlled in cooperation with the tractor via sensors mounted in the kingpin (a type of shaped pin with a cylindrical head—editor’s note). “The sensors record the longitudinal and transverse forces acting on the kingpin, convert these into digital signals, and transmit them to the vehicle, where the onboard computer controls the axle in real-time,” adds Michael W. Nimtsch.
Combustion reduced by 40%
The intelligent Trailer Dynamics eTrailer electric drive system supports the tractor throughout the entire journey, both when starting and climbing hills. If all the energy is not needed for these tasks, the electric drive uses the remaining energy to continuously assist the tractor along the route. Depending on the load and topography, the eTrailer’s electric assistance can reduce diesel consumption and CO2 emissions by an average of 40% or around 40 tonnes of CO2. When combined with a battery-powered tractor unit (BEV), the eTrailer can double or even triple the range.
The key advantage of this technology is its universal application, much like a USB connector. The eTrailer can be connected to vehicles with all types of engines—whether hydrogen, electric, or diesel—regardless of the manufacturer.
Pioneers in their field
In addition, Trailer Dynamics has launched a project to introduce Battery Swapping Technology (BST) for electrified trailers in Europe. They are working on this with DB Schenker and the Chinese electric vehicle battery manufacturer CATL. Trailer Dynamics sees major benefits for logistics in this technology:
- Battery exchange time of just 5 minutes per module
- Cost reduction through a pay-per-use model, where the eTrailer can be purchased without batteries
- Longer battery life, as batteries charge slowly in the exchange system
With this solution, once the battery in the semi-trailer is quickly replaced with a pre-charged one, the vehicle can continue its journey without having to wait several tens of minutes for a recharge.
Currently, the partners are exploring how battery swap stations can be configured and implemented to meet the future demand for electrified trailers and potentially electrified trucks across Europe. A battery swap station is already operational in China.
Chinese battery manufacturer CATL will bring its battery expertise to the eTrailer concept and provide critical technical data for the design of the battery swap stations. Meanwhile, Trailer Dynamics will oversee the mechanical and electrical integration of swappable batteries into the vehicle systems and will provide prototypes for testing.
“In 2025, we will launch the first few hundred vehicles in an initial series,” says Michael W. Nimtsch.
DB Schenker will identify suitable locations for testing battery swap stations and create a prospective map of potential locations across Europe.
“Battery swapping technology has the potential to maximise the uptime of our vehicles and reduce CO2 emissions across Europe,” says Abdullah Jaber, CEO of Trailer Dynamics.
In the future, the group of participating partners is expected to expand to include more logistics companies, energy suppliers, and service providers. Series production of the Trailer Dynamics eTrailer is anticipated to begin in 2026.