Finally! Innovation For Semi Truck Trailers - Range Energy Is Electrifying Trailers To Extend Range

TL;DR

Range Energy retrofits semi-truck trailers with electric powertrains and battery packs, cutting diesel fuel use by up to 65% and adding 100+ miles of range to electric tractors.

Key Points

• 1.Range Energy electrifies existing trailers rather than replacing them. The retrofit installs a 300 kWh (refrigerated) or 200 kWh (dry van) battery pack plus a ZF AxTrax 2 e-axle in about 4 hours with two techs and standard tools — no new trailer purchase needed.
• 2.The system cuts diesel fuel consumption by up to 65% on refrigerated routes. Roughly 40% comes from powering the tractor assist, and an additional 20–25% from eliminating the diesel-powered refrigeration unit by using captured regen energy instead.
• 3.Cisco (Sysco Foods) is the flagship launch customer. Range Energy chose refrigerated fleet trailers as the go-to market because eliminating the always-on diesel TRU provides the strongest combined fuel savings and decarbonization case.
• 4.The ZF AxTrax 2 e-axle delivers 200–250 kW continuous power. Originally designed for electric buses and primary movers, it was adapted for trailer use with modified gearbox internals, different track width, and updated suspension pickup points; it operates as a 2-speed in this application.
• 5.Payback period is currently around 2 years at $4.50/gallon diesel. At the nominal 4–5 year payback, fleets save $25,000–$40,000 net per year after charging costs; every $1/gallon diesel price increase cuts the payback period by roughly one year.
• 6.The trailer adds at least 100 miles of range to an electric tractor when connected. Most daily routes are 160–280 miles, and the system enters a mild-hybrid regen mode after ~300 miles to continue powering refrigeration even on longer runs.
• 7.No CAN bus connection to the tractor is required — the system works with any diesel or electric truck. Driver intent is inferred through onboard IMUs and native trailer sensors, abstracting away direct strain-based sensing after hundreds of thousands of miles of testing.
• 8.The system is fully reversible and modular, targeting 3.5 million class-8 trailers in North America. It supports two-way power (24V lift gate, cameras, accessories), charges via CCS Type 2 at up to 150 kW DC, and first customer deliveries to Cisco and others are planned for end of 2024.