Trenergy: Trailer Design Assessment for optimizing energy consumption

To meet the European Green Deal, new CO2 emission standards for Heavy-Duty-Vehicles (HDV) have been set. The amended Regulation EU-2019/1242 has a wider scope, covering not only lorries but also trailers. From 2030 on (semi-)trailers must reduce their emissions by 10%, even though trailers generally do not emit any CO2-emissions. But how can a trailer save CO2?
To calculate emissions, the European Commission has developed VECTO, the Vehicle Energy Consumption Calculation TOol. It is a standardized framework designed to determine fuel consumption and CO2-emissions of HDVs. Analysis show that the two main focus points for CO2 reduction, based on VECTO, are weight reduction and improved aerodynamics. However, equipping trailers with aerodynamic devices or making them lighter isn’t straightforward. Trailers lead a rough life and the industry is adapted to the current trailer designs. Lightweight constructions might harm the lifetime of a trailer and trailers with protruding aerodynamic parts won’t fit on a train anymore. Besides, both solutions have a major influence on the vehicle (roll-over) stability and therefore safety. It is not that evident for a trailer manufacturer to design a (new) trailer that 1) fulfills the CO2 regulations, 2) complies with the constructional requirements and 3) remains safe and stable.
This 3-step-approach is really missing for trailer manufacturers, and this is endorsed by Burgers Carrosserie: “How can we validate (upfront) that the trailer is still as “strong” and “safe” if we apply the weight reduction that shows sufficient CO2 saving in VECTO?”. The answer was simple, it isn’t.
It is the aim of Trenergy to develop this 3-step approach with complementary simulation tools, where trailer manufacturers can validate their design(s) for CO2 Savings, Construction and Safety. It is intended to make the developed models/tools open source for the Logistic Industry.

Eindrapportage

It was the aim of Trenergy to develop a 3-step approach with complementary simulation tools, where trailer manufacturers can validate their (new) trailer design(s) for CO2 Savings, Construction and Safety. Trailer manufacturers like Burgers Carrosserie (now known as Royal Burgers) are looking for complementary simulation tools such that they can have a 3-step approach before building/developing a new trailer. CEO of Burgers: “How can we validate (upfront) that our trailer is still sufficiently “strong / stiff”, while remaining “safe / stable” if we apply weight reduction that shows a certain CO2 saving based on VECTO?

This envisioned 3-step approach should help trailer manufacturers in answering the questions below, and it was intended to make the developed models/tools open source.
1) What is the effect of weight reduction in terms of CO2 savings in relation to VECTO?
2) Does this lighter trailer still comply with constructional requirements?
3) Is the lighter trailer still safe/stable in terms of roll-over-stability?

The Trenergy project has researched every step individually and the outcomes are explained in more detail in a report. To summarize them:
• Step 1 (CO₂ estimation): Successfully achieved. A simplified relationship was developed to estimate CO₂ impacts from trailer weight reduction, providing fast and reasonably accurate results compared to full VECTO simulations, though sensitive to input assumptions.
• Step 2 (structural assessment): Not achieved as a standalone tool. Reliable evaluation of strength and stiffness requires detailed FEM analysis and OEM-specific expertise, making a generic simplified tool insufficient. The capability is best handled within OEM engineering processes.
• Step 3 (stability analysis): Partly achieved. Multi-body simulations show limited impact of weight and stiffness changes on rollover stability under simple test conditions. However, it was found that roll-over is affected by a complex interaction of vehicle parameters. While the models are effective, they are too complex for plug-and-play use due to high data and expertise requirements.