Australia’s first Powered Trailer System launches in South Australia
South Australian company VE Motion has launched Australia’s first commercially available driven powered trailer system, giving heavy transport operators a new way to cut fuel costs, improve efficiency and boost performance without replacing existing trucks.
The VE Motion Powered Trailer System electrifies the trailer rather than the prime mover, delivering propulsion assist, regenerative braking and onboard power for trailer-based systems. The result is significantly lower diesel use, improved vehicle performance and reduced emissions, while continuing to operate with existing truck fleets.
The system has been engineered, integrated and brought to market in South Australia, with the powered trailer systems built and assembled in Murray Bridge.
VE Motion Co-founder and CEO Dean Panos said the idea for the system came from a simple observation that diesel remains the most expensive and highest-emission fuel in Australia’s energy mix, yet it still powers almost all heavy transport.
“From our background in power generation, it was clear that electrification makes sense for heavy transport from an operating cost perspective,” Mr Panos said.
“The problem is that full-electric trucks come with very high capital costs, added mass, range limitations and operational disruption. That is why uptake has been almost non-existent.”
Mr Panos said powered trailers offered a practical alternative.
“They deliver real fuel savings, of up to 50% on diesel, more power and better efficiency, without forcing operators to replace fleets or change how they work.
That is why we built VE Motion, to make that solution work for Australian conditions.”
Co-founded by Dean Panos and Stephen Bussenschutt, VE Motion designs and builds heavy duty trailers as well as electrified systems, giving the team firsthand experience into what freight operators need on the road.
“Our motivation was to rewrite the value equation for the transport industry,” Mr Panos said.
“We did not want hype or theory. We wanted to build something useful – equipment that cuts fuel use, reduces emissions and improves performance, without adding headaches. The industry does not want disruption. It wants gear that works.”
The VE Motion Powered Trailer System is now commercially available and has been demonstrated operating on South Australian roads as part of a heavy vehicle combination.
Unlike full-electric vehicles, the system operates as a plug-in hybrid. It provides electric propulsion and energy recovery when conditions allow, and can operate in diesel only mode when required, ensuring vehicles are never stranded by range or charging constraints.
“All of the system integration, control architecture, development and testing has been done here in South Australia,” Mr Panos said.
“We have taken proven componentry and engineered a complete system around Australian routes, loads and conditions. This is a locally built solution for local operators.”
VE Motion has invested more than $4 million since 2018 into research and development, engineering, prototyping, compliance and real-world validation to bring the powered trailer system to market.
HOW IT WORKS
The VE Motion Powered Trailer System is supplied as a complete modular kit that can be fitted to new or existing heavy-duty trailers. Installation can be carried out by freight operators or trailer manufacturers using familiar components and processes.
Rather than electrifying the prime mover, the system places propulsion, energy storage and control systems directly on the trailer.
The system includes:
- E-axle – featuring a 295kW Linamar electric drive unit, integrating motor, gearbox and inverter into a compact assembly with a Gross Axle Weight Rating of up to 10 tonnes.
- Scalable battery packs known as Rechargeable Electrical Energy Storage Systems (200kWh, 400kWh and 600kWh) mounted between the trailer chassis rails on custom brackets.
- Embedded control and safety systems, including a Battery Management System, Safety Contactor Box, Power Distribution Unit and Vehicle Control Unit.
During operation, the powered trailer provides propulsion reducing load on the prime mover. Regenerative braking captures energy normally lost during braking and stores it in the battery system. The system can also power trailer based auxiliary systems such as pumps, blowers and refrigeration units without requiring the prime mover to idle.
Because the system supplements, rather than replaces, the internal combustion engine, trucks can continue operating even if battery charge is depleted.
MAJOR SAVINGS AND ENVIRONMENTAL BENEFITS
VE Motion estimates the powered trailer system can deliver substantial operating cost and environmental benefits including:
- Up to 50% reduction in diesel consumption
- Offset of 80 to 300 tonnes of carbon emissions per vehicle per year
- $50,000 to $200,000 in annual diesel savings annually (up to 125,000 litres)
- Reduce engine, brake and retarder wear
- Reduce noise and tailpipe emissions
- improved acceleration, hill climbing, gradability and startability
- Approximately 400 horsepower of propulsion assist improving productivity and reducing cycle times.
This project is supported by the Australian Government’s Industry Growth Program.