Supporting heavy-duty electric vehicle production through a modular approach

Here, Robert Weirauch, Senior Product Manager at HUBER+SUHNER, gives his insights into how a modular approach to production can support the electrification of heavy-duty vehicles and alleviate some of the common challenges faced by manufacturers in today’s competitive market.

Take Europe as an example. According to figures published by the ACEA, the European zero-emission city bus market grew by 45% within the first half of 2024 alone, with both Germany and Spain on a growing trajectory. In 2023, the same market saw a 53% growth in registrations. Over 42% of city buses are now zero-emission – including Battery Electric Vehicles (BEVs) and hydrogen – nearly three times more than the 15% in 2020.

It's not just buses either: electric truck sales are also gradually gaining momentum. These sales are being bolstered in part due to a number of strong and ambitious policies and regulations being rolled out worldwide. The European Commission (EC)’s recent climate target, for example, has recommended a reduction of the European Union (EU)’s net greenhouse gas emissions by 90% by 2040. This target is intended to help the region reach climate neutrality by 2050, and the use of electric trucks and buses can play a pivotal role in achieving this.

Overcoming key challenges

This is just one reason why bus and truck manufacturers are concentrating their efforts on bringing electric vehicles to the mass market for all vehicle segments, including long-haul operations. As you would expect, this has resulted in significantly high production volumes, which will only continue to increase as these vehicle types grow in popularity.

This places increased pressure on manufacturers to meet customer demands, not only in terms of delivery times, but performance too. Not only must they find a way to reduce the overall assembly manufacturing times and optimise the cable assembly process, but find innovative methods of obtaining the maximum performance levels out of cables and connectors too. They must also avoid electromagnetic compatibility issues when in use too.

Yet all too often, vehicle manufacturers focus on the direct costs of their solutions, without paying enough attention to indirect production costs such as assembly, test and production equipment, or even reworks. To overcome these issues, a modular approach to electric vehicle production is essential.

A new era of vehicle production

Since the very beginning of the migration towards electric vehicles, solution providers such as HUBER+SUHNER have been preparing new products and increasing high-voltage competency. As a result, a number of major Original Equipment Manufacturers (OEMs) and key connector suppliers are entering partnerships with these businesses to drive further transformation within the realm of vehicle production.

These partnerships have led to the introduction of innovative technologies which are helping manufacturers to maintain exceptional vehicle quality. For example, competitive high-voltage solutions for commercial vehicles, such as RADOX technology, customised and modular distribution boxes (HVDU), power splitters (HVPS) and modular cable assemblies (mCAY) have all entered the market in recent years, and are evolving the way these vehicles are made and perform.

Solutions in action

RADOX technology has been adapted widely by industry leaders worldwide, due to the thermal, mechanical, and chemical properties it provides manufacturers. Describing the process of crosslinking thermoplastic polymers by electron beams, RADOX cable technologies do not melt, possess greater abrasion and cut resistance than conventional cables, and are extremely resistant to various environmental factors, including UV exposure, weathering, oil, and water to name a few.

The concept of a modular approach has also changed the cable assembly process. Manufacturers are now moving beyond traditional crimp technology and using Electromagnetic Pulse Technology (EMPT), which applies short, high-powered electric currents in order to join and form conductive materials within connection systems. This process does not introduce any significant heat into connection points, meaning any materials used will retain full strength and be perfectly suitable for harsh environments and for delivering high-quality electrical performance over its lifetime.

Future modularity

For efficient modularisation, OEMs are also turning to modular cable assemblies during the development process. Because modular manufacturing involves building vehicles from pre-assembled components, these ready-to-install assemblies can help reduce production times and get vehicles to market faster, as less time and manpower is required for retooling and refitting production lines. These assemblies – which come ready-to-install onto serial vehicles – have also been validated according to the latest automotive standards, alleviating safety and performance concerns.

The electrification process is also aided through the use of online product configurators, which offer manufacturers the means to tailor products to their exact specifications. Able to choose from various cable types and sizes, this approach means modular cable assemblies can be customised quickly and efficiently, accelerating both the purchasing and manufacturing process. In effect, it supports manufacturers’ electrification needs, and shortens deliver times on commercial electric vehicles.

We’ve also seen new high-voltage power distribution boxes grow in prominence recently. These intricate modular systems guarantee secure power distribution for all high-voltage components found within BEVs, fuel cell electric vehicles (FCEVs) and hybrid vehicles. The use of a mHVDU, especially when combined with RADOX cable technology, can further optimise the performance of commercial vehicle types such as e-trucks and e-buses.

Modularisation is no longer a far-flung concept – it’s bringing real, demonstrable results to OEMs across the globe. By forming close links with component vendors and adopting this approach, manufacturers can better manage indirection production costs and simply the entire process, while leveraging industry expertise to meet current market demand. Already growing in prominence, modular manufacturing will undoubtedly play a significant role in the evolution of the automotive industry over the next decade and beyond.