WATCH + LISTEN + READ: 3 Benefits of Chassis Designed Specifically for Commercial EVs
According to Wikipedia, “Workhorse Group Incorporated, originally AMP Electric Vehicles, is an original equipment manufacturer and technology company headquartered in Sharonville, Ohio, U.S. Workhorse makes commercial electric vehicles and telematics software designed for last-mile delivery. Their products include commercial electric vehicles and the Metron telematics software system.” But that just scratches the surface of what’s happening at the four facilities Workhorse operates.
For most of its history, Workhorse had been more of an R&D company that was developing advanced technology. Around 2020, the company made the decision to establish itself as an OEM that could produce in volume a steady, reliable commercial EV product to the market.
“I came to the company about three years ago because we wanted to develop a brand-new product and relaunch as a full OEM,” says Josh Anderson, the CTO at Workhorse, “Workhorse is an electric last-mile delivery truck and chassis manufacturer with a long and varied history. The company has been around for about 10 years in its current configuration, but the history of the company goes back almost 100 years.”
The type of chassis Workhorse builds are purpose-built for commercial electric vehicles (EVs). Purpose-built chassis offer a multitude of advantages that can significantly improve the performance, efficiency, and overall value of these vehicles. Unlike repurposed internal combustion engine (ICE) chassis, EV-specific chassis are designed to maximize the benefits of electric powertrains.
“One of the key innovations of Workhorse’s flagship product, the W56 Stepvan, is its regenerative braking system,” explains Anderson. “This system differs from traditional braking systems in that it captures kinetic energy during braking and converts it back into electricity to recharge the battery. This not only reduces wear and tear on the brakes, but also increases the range of the vehicle.”
Looking at three of the benefits associated with EV purpose-built chassis, and regenerative braking specifically, we see two obvious benefits and one hidden gem.
Reduced wear and tear on traditional braking components. By converting kinetic energy into electricity during deceleration, regenerative braking reduces the reliance on traditional friction brakes, resulting in significantly less wear and tear on components like brake pads and rotors, thus extending their lifespan and reducing maintenance requirements.
Extended driving range. Regenerative braking systems can be seamlessly incorporated into the vehicle’s architecture, allowing for more efficient energy recapture during deceleration.
“The amount of energy recovered through regenerative braking depends on various factors, including the weight of the vehicle and driving habits. Workhorse has seen a 30% recovery rate in many of its delivery routes.” says Anderson. “With a diesel truck, you can’t put fuel back in your tank by stepping on the brakes. But with regenerative braking, you can.”
Developing better driving habits. Ironically, learning to get the most ROI from a regenerative braking system translates to brake longevity with traditional brakes as well.
“Some people may just use traditional braking habits because they’re not really confident in how regen brakes work,” opines Anderson. “If you slam on the brakes all the time, you may not see any benefit at all. But people who learn to let the motor do the work can really see substantial savings, particularly with stop and go delivery.”
As drivers learn to pay more attention to how their vehicle behaves under different load and braking conditions, they tend to be easier on brake parts, no matter whether traditional or regenerative.
The Future of Workhorse’s EV Purpose-Built Chassis
Regenerative braking and EV purpose-built chassis have aspects that contribute to reduced total cost of ownership (TCO), and Workhorse’s W56 Stepvan has been well-received in the market, with fleets appreciating its reliability and performance.
Workhorse is currently focused on expanding the portfolio of the W56 by offering multiple wheelbase versions, adding features, and developing specialized versions such as refrigerated units. The company is also exploring adjacent markets for its powertrain technology.