EV Technology for Heavy-Duty Applications

Batteries capable of fast charge hold great interest for electrification of multiple heavy-duty applications. These require many charge–discharge cycles, often high-discharge power, and limited trade-off of energy density. Fast charge supports higher uptime and work rates. Nyobolt is working with partners in robotics, mining, and construction to implement batteries capable of 5–10-minute full SOC charging, high cycle life, and acceptable thermal attributes. Technology and implementation efforts are described.

Tyfast delivers high-performance lithium-ion battery solutions for heavy-duty trucking, mining, and construction vehicle applications. Powered by a proprietary vanadium-based anode, the batteries enable ultra-fast charging (<6 minutes to 80% SOC), exceptional cycle life (>10,000 cycles), and reliable operation across a wide temperature range (-40°C to 70°C). Having passed safety tests, the technology also reduces vehicle downtime and total cost of ownership—making heavy-duty electrification both practical and economically viable.

Unlike light-duty EVs, commercial electrification requires batteries designed for lowest total cost of ownership (TCO). Working with 21st Century Truck Partnership, DOE’s HD-VOLTS Program is working to establish battery cell-design requirements based on vehicle drive cycles, range, fast charging, lifetime, and energy density. We identify opportunities for LFP, NMC, and emerging battery chemistries to meet medium- and long-term vehicle needs with lowest TCO.

As the industry pushes toward electrification, hybrid battery systems are emerging as a practical stepping stone, especially for heavy-duty trucks where range, cost, and charging infrastructure remain major hurdles for full BEV adoption. The electrochemistry considerations, trade-offs, and performance requirements in cell design for hybrids differs to that of BEV, which will be discussed in the various levels of hybridization as investigated at Accelera.

The route to supporting Fortescue’s pathway to net-zero by 2030 requires the deployment of high-performance batteries into a fleet of off-highway electric vehicles. These offer unique challenges for being able to address decarbonization. At Fortescue Zero, we are leveraging our experience in the system design and development of high-performance batteries, including motorsports and off-road BEV systems, to accelerate the electrification and engineering of heavy-duty and mining vehicles.

Development and validation of commercial vehicle battery cells requires detailed understanding of the expected system design and use cases for the cells, in the context of battery packs, pack systems and full vehicles. Following up on last year's presentation about requirements-based design for commercial-vehicle-specific battery cells, the presentation will discuss challenges and approaches toward development and validation of cells and will provide a progress update.

Battery-electric heavy-duty vehicles face very different challenges in a mining environment compared to on-road BEVs. This talk will give an overview of typical duty cycles that actual, deployed underground mining BEV fleets see, how a vehicle–battery–charger system is optimized for this type of application, and what OEMs are looking for in emerging battery technology to enable the next horizon of improvements.

Mining presents one of the most demanding use cases for electrification, with aggressive duty cycles, limited charging windows, and extreme sensitivity to downtime. This presentation explores how Elysia's battery intelligence platform enables high-performance systems at scale by applying insights from motorsport and automotive to the unique challenges of heavy industry. We highlight why both traditional datasheet-based methods and motorsport-derived fast-charge strategies fall short when deployed across large, variable cell populations. Through case studies in Formula E, luxury electric vehicles, and battery-electric haul trucks, we show how embedded and cloud-based health prognostics enable a step change in safety, faster charging, longer life, and higher uptime across sectors. Battery intelligence is not just a differentiator, it’s a requirement for delivering performance in real-world electric fleets.

This presentation covers Hyundai's commitment to clean logistics in the U.S. through early deployments of electrified commercial vehicles. The presentation showcases the real-world performance of the XCIENT Fuel Cell heavy-duty truck, deployed in projects like NorCAL ZERO and HTWO Logistics. The presentation also outlines a strategy to develop the necessary hydrogen infrastructure, including refueling stations and strategic partnerships, to support scalable, sustainable freight operations.

As battery electric buses (BEBs) become more common, ensuring fire safety is more important than ever. This session will highlight the latest advancements in fire detection and suppression technologies designed to prevent and contain thermal runaway events. However, technology alone isn’t enough—training for fleet operators, maintenance teams, and first responders is essential to properly manage battery risks and follow evolving safety procedures. By integrating cutting-edge suppression systems with comprehensive workforce education, the transit industry can enhance the safety, reliability, and resilience of electric bus fleets, protecting both people and vehicles as the shift to zero-emission transportation continues.

This presentation explores how ABM delivers end-to-end EV charging solutions by integrating planning, design, installation, and maintenance. Attendees will gain insights into navigating utility coordination, securing funding, managing loads, and implementing future-proof strategies. Through real-world case studies, smart charging technology, and integration with sustainability goals, the session highlights how ABM ensures safety, compliance, and 24/7 support to maximize performance, user satisfaction, and long-term value.

On the surface, fleet and heavy-duty vehicle charger infrastructure needs appear to be the same as passenger vehicle on-route needs. While they have much in common with each other, there are still significant differences. This presentation will explore some key aspects of products, along with deployment considerations that are critical to fleet charging infrastructure.