Innovating Hybrid Power: Simulation, Testing, and Regulatory Compliance of a Patented Series-Parallel Heavy-Duty Truck
Published in 12th International Engine Congress 2025, 2025
This work was presented at the 12th International Engine Congress 2025 ATZ 2025 in Baden-Baden, Germany.
Abstract
The patented Brudeli Powerhybrid™ hybrid powertrain is currently undergoing testing on Norwegian roads to demonstrate its emission reduction potential. A series-parallel hybrid powertrain is installed on a DAF CF 410 tractor, combining an 11-L diesel engine with two electric motors power (2 × 130 kW continuous). Extended electric driving will be obtained with a 200-kWh battery, replacing otherwise low efficiency engine operation and optimizing fuel use.
Power boosting, energy harvesting, and pure electric driving will be tested and their individual contributions to improving efficiency will be discussed and compared against simulations.
Initial analysis shows that Brudeli’s Powerhybrid can meet the latest European and American emission regulations. Different CO2 credits (VECTO) can be obtained, based on which system configuration is used for certification on the European market. Additionally, the relevance of Brudeli’s systems will be considered in the context of their attractiveness for meeting EPA’s 2027 Greenhouse Gas (GHG) Phase 3 requirements in the US market.
Long haul routes, where trucks need to drive 30+ tons of cargo for 300+ km daily, emit a substantial CO2 and present serious challenges for the range capabilities of BEVs. With hybrids, CO2 emissions can be reduced significantly or even eliminated in congested areas. Alternative fuel engines can be integrated into the Brudeli Powerhybrid™ system, contributing to gradual scaling of production and distribution capabilities of such fuels.
The Brudeli Powerhybrid™ will create a cost competitive business opportunity for carbon neutral trucks with green fuels against diesel trucks. Optimally combining Brudeli Powerhybrid™ to downsized combustion engines running on green fuels, provides a feasible strategic pathway to reduced energy consumption and emissions in heavy duty trucking. Brudeli Powerhybrid™ offers 50–80 % CO2 reduction for diesel trucks, meeting European and American regulations, without overlooking operational and economical aspects.
From the simulations it is plausible to conclude that even with a battery as small as 200 kWh to target fuel saving in the range of 50% is realistic. Results from the testing of the pilot truck give clear indications that targeting 50% fuel saving would be within reach for specific use cases.
Recommended citation: Brudeli, G., de Souza Rebouças, G.F., Vestgaard, B., Fagerås, H.F. Innovating Hybrid Power. In: Heintzel, A. (eds) Internationaler Motorenkongress 2025. Int.Engine.Congr. 2025 2025. Proceedings. Springer Vieweg, Wiesbaden.
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