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, the total cost of ownership (TCO) and maximum vehicle availability are crucial metrics. When transitioning to electromobility, the focus shifts to the efficiency of each individual vehicle. A central technology for this is recuperation during electric driving. This principle of regenerative braking has existed for over 100 years and is more important today than ever before. It makes it possible to considerably increase the range of e-vans while significantly reducing maintenance costs, which directly contributes to TCO optimization.
Basics of Regenerative Braking: More Than Just Braking
Recuperation refers to the technical recovery of energy. In an electric vehicle, the electric motor functions as a generator during this process. When the driver takes their foot off the accelerator pedal, the kinetic energy of the vehicle is not simply converted into unused heat at the brake discs. Instead, the motor reverses its function and feeds a significant portion 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-go operations per day. The technology is an essential component to maximize the real range of electric vehicles. Each braking process thus becomes a small charging process for the 137 kWh battery.
The strength of the recuperation can be adjusted in several levels in many vehicles. A high level enables so-called one-pedal driving, in which the vehicle decelerates sharply as soon as the foot is removed from the pedal. This maximizes energy recovery and protects the mechanical braking system, which can extend maintenance intervals by thousands of kilometers.
Efficiency in practice: where regenerative braking reaches its full potential
The effectiveness of recuperation depends heavily on the driving profile and topography. In city traffic with speeds below 50 km/h and frequent braking maneuvers, the potential for energy recovery is greatest. Here, fleet vehicles can typically increase their range by 15-20 %, which can mean an additional buffer of almost 100 km for a HEERO eTransporter with a range of up to 500 km.
On highway drives at constantly high speeds, the effect is smaller as braking occurs less frequently. Nevertheless, recuperation still contributes to efficiency here, for example in stop-and-go traffic or on downhill slopes. Modern systems intelligently adapt the recuperation performance to the driving situation. The technical limit of recuperation power is often between 50 and 90 kW in order to ensure the safety of the vehicle battery.
For fleet operators, analyzing the deployment profile is crucial. A typical deployment analysis highlights the following advantages:
Urban passenger transport and delivery services: Maximum recuperation, range increase is substantial.
Municipal services (e.g. waste collection): High potential due to constant stopping, significantly more efficiency.
Regional distribution transport: Moderate potential, range gain of around 10-15 %.
Long-distance and highway driving: Lower potential, approx. 5-8 % energy recovery.
This data is essential for precise route planning and calculating the WLTP range of commercial vehicles. In this way, recuperation becomes a calculable factor for cost-effectiveness.
TCO Reduction: Direct cost benefits through regenerative braking
Recuperation in electric driving lowers total cost of ownership (TCO) in two ways. The first and most obvious advantage is the reduction in energy consumption. A noticeably higher efficiency through recuperation means annual savings of several thousand euros in electricity costs for a fleet of 20 vehicles.
The second, often underestimated benefit, is the massive reduction in wear on the mechanical brake system. Since the electric motor does most of the deceleration work, brake discs and pads are subjected to significantly less stress. This leads to much longer maintenance intervals and lower costs for spare parts. For a single vehicle, the savings on brakes can add up to over 1,500 euros over a retention period of 5 years.
The conversion from HEERO is designed to maximize these benefits for demanding fleet operations. The system calibration for the Sprinter (models 313, 316, 319, 324) ensures that recuperation is optimally matched to the vehicle weight and typical usage profiles. The possibility of bidirectional charging will play an even greater role in the future. The energy gained through recuperation can potentially contribute to grid stabilization.
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.
More useful links
The NOW GmbH offers a guide to action for electromobility in fleets.
The Fraunhofer ISI presents a study on the topic 'Get eReady', which likely deals with electromobility.
The Federal Ministry for Economic Affairs and Climate Action has published an efficiency study for passenger cars.
Strategy& (PwC) highlights the breakthrough of e-trucks in an article.
The dena (German Energy Agency) provides a dossier on the expansion of charging infrastructure for e-trucks.
The Federal Environment Agency has issued a publication on fleet target values.
The Fraunhofer LBF provides information in a press release about hybrid storage systems for maximizing the charging efficiency and range of semi-trailer trucks.
The VDA (German Association of the Automotive Industry) has submitted a statement to the Bundestag.
