Regenerative braking in electric driving: lower TCO and maximise fleet range
Regenerative braking is a key technology for improving the efficiency of electric fleets. It converts braking energy that would otherwise be lost into usable range.
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The topic briefly and concisely
Regenerative braking can significantly increase the range of electric commercial vehicles, especially in urban traffic, and thus enhance operational reliability.
Thanks to energy recovery, brake wear is significantly reduced, which directly lowers maintenance costs and therefore the TCO.
The efficiency of recuperation is a predictable factor that, through analysis of the driving profile, optimises route planning and fleet efficiency.
For fleet operators, total cost of ownership (TCO) and maximum vehicle uptime are key metrics. When switching to electric mobility, the efficiency of each individual vehicle comes into focus. A core technology for this is regenerative braking in electric driving. This principle of recovering braking energy has existed for over 100 years and is more important than ever today. It makes it possible to significantly increase the range of electric vans while at the same time substantially reducing maintenance costs, which directly contributes to TCO optimisation.
Basics of Regenerative Braking: More Than Just Braking
Regenerative braking refers to the technical recovery of energy. In an electric vehicle, the electric motor acts as a generator during this process. When the driver lifts their foot off the accelerator pedal, the vehicle's kinetic energy is not simply converted into unused heat at the brake discs. Instead, the motor reverses its function and feeds a significant proportion of the braking energy back into the vehicle battery as electrical current.
This process significantly increases the efficiency of the overall system. This advantage is particularly effective in urban delivery traffic, with its hundreds of stop-and-start manoeuvres per day. The technology is a key building block for maximising the real-world range of electric vehicles. Every braking action therefore becomes a small charging process for the 110 kWh battery.
The strength of regenerative braking can be adjusted in several stages in many vehicles. A high setting enables the so-called one-pedal driving, in which the vehicle decelerates strongly as soon as the foot is lifted from the pedal. This maximises energy recovery and protects the mechanical braking system, which can extend service intervals by thousands of kilometres.
Efficiency in practice: where regenerative braking reaches its full potential
The effectiveness of regenerative braking depends heavily on the driving profile and the topography. In urban traffic with speeds below 50 km/h and frequent braking manoeuvres, the potential for energy recovery is at its greatest. Here, fleet vehicles can typically increase their range by 15-20%, which in a HEERO e van with up to 500 km of range can mean an additional buffer of almost 100 km.
On motorway journeys at consistently high speeds, the effect is smaller because braking is less frequent. Nevertheless, regenerative braking also contributes to efficiency here, for example in slow-moving traffic or on downhill sections. Modern systems intelligently adapt the regenerative braking output to the driving situation. The technical limit of regenerative braking output is often between 50 and 90 kW, in order to ensure the safety of the vehicle battery.
For fleet operators, analysing the duty profile is crucial. A typical usage analysis shows the following benefits:
Urban passenger transport and delivery traffic: Maximum recuperation, significant range increase.
Municipal services (e.g. waste collection): High potential through constant stopping, significantly greater efficiency.
Regional distribution traffic: Moderate potential, range gain of around 10-12%.
Interurban and motorway journeys: Lower potential, approx. 5-8% energy recovery.
This data is essential for precise route planning and the calculation of WLTP range of commercial vehicles. This makes regenerative braking a predictable factor in economic efficiency.
TCO Reduction: Direct cost benefits through regenerative braking
Regenerative braking in electric driving reduces total cost of ownership (TCO) in two ways. The first and most obvious benefit is the reduction in energy consumption. Noticeably higher efficiency through regenerative braking means an annual saving of several thousand euros in electricity costs for a fleet of 20 vehicles.
The second, often underestimated, benefit is the substantial reduction in wear on the mechanical braking system. As the electric motor handles the majority of the deceleration effort, brake discs and pads are subjected to significantly less stress. This leads to noticeably longer service intervals and lower costs for spare parts. For a single vehicle, the savings on the brakes over a holding period of 5 years can amount to more than €1,500.
Heero's D2E conversion is designed to maximise these benefits for demanding fleet operations. The system calibration for the Sprinter (models 313, 316, 319, 324) ensures that regenerative braking is optimally matched to the vehicle weight and typical usage profiles. The option of bidirectional charging will play an even greater role in the future. The energy recovered through regenerative braking can potentially contribute to grid stability.
More useful links
NOW GmbH offers a practical guide to electromobility in fleets.
Fraunhofer ISI presents a study on the topic of 'Get eReady', which probably deals with electromobility.
The Federal Ministry for Economic Affairs and Climate Action has published an efficiency study for passenger cars.
Strategy& (PwC) examines the breakthrough of electric lorries in an article.
dena (German Energy Agency) provides a dossier on expanding the charging infrastructure for electric lorries.
The Federal Environment Agency has published a paper on fleet target values.
Fraunhofer LBF reports in a press release on hybrid storage systems to maximise charging efficiency and range for articulated lorries.
The VDA (German Association of the Automotive Industry) has submitted a statement to the Bundestag.
FAQ
How much additional range do I really gain through recuperation?
The actual increase in range depends heavily on the operating profile. In urban passenger transport or delivery operations with many stops, significantly higher gains are realistic. For pure motorway driving at a constant speed, the figure is typically 5-8%. Anticipatory driving maximises the effect in every scenario.
Does regenerative braking completely replace the mechanical brake?
No, the mechanical brake remains fully in place as a safety-critical system and is generally activated during heavy braking or emergency braking. Regenerative braking, however, handles the majority of everyday deceleration processes up to a certain limit, which helps protect the mechanical components.
Does regenerative braking also work when the battery is fully charged?
When the battery is charged to 100%, no further energy can be absorbed. In this case, the vehicle management system reduces the regenerative braking output and primarily uses the mechanical brake to slow the vehicle. After a few kilometres of driving, full regenerative braking output is available again.
Can I adjust the level of regenerative braking in a HEERO vehicle?
Yes, the HEERO systems generally allow different recuperation levels to be set. This enables the driver to adapt the driving behaviour to the respective situation – from strong deceleration for maximum energy recovery in city traffic to freewheeling "sailing" on interurban journeys for the highest level of comfort.
How does recuperation affect my fleet’s maintenance planning?
Recuperation significantly extends the service life of brake discs and pads. Fleet managers can expect much longer maintenance intervals for the braking system, which not only reduces costs but also cuts vehicle downtime, thereby increasing vehicle availability by several days per year.
What is the difference between regenerative braking and 'one-pedal driving'?
Regenerative braking is the underlying technology behind energy recovery. 'One-Pedal Driving' is a driving style made possible by a very high regenerative braking setting. In this mode, deceleration when lifting off the accelerator is so strong that the brake pedal is hardly needed in normal traffic flow.
