Hyliion’s ERX Hypertruck: A Here-Now Solution to BEV Range Problems - Equipment

Hyliion’s ERX Hypertruck: A Right here-Now Answer to BEV Vary Issues – Gear



Hyliion’s natural-gas-powered ERX Hypertruck is step one in a journey towards a fuel-cell-powered zero-emissions transportation answer.

Picture: Hyliion


The Dec. 20 launch of the Environmental Safety Company’s remaining rule on diesel engine emissions brings into fairly sharp focus the necessity to discover alternate options to diesels. The pathway to an all-electric future is starting to take form, however pure-electric long-haul vehicles are nonetheless a great distance out.   

Stiffening emissions requirements will drive each value and complexity. Whereas a lot of the duty for adhering to those requirements will fall on the truck and engine makers, fleets will share that burden, with increased prices and sure further upkeep procedures. (Hopefully it gained’t be as dangerous as when fleets turned know-how guinea pigs after 2007 emissions requirements went into impact.)

Is there such a know-how on the horizon, one which’s someplace between diesel and totally electrical, that meets business wants whereas checking all of the environmental bins? It is perhaps Hyliion’s Hypertruck ERX.

I believe Hyliion founder and CEO Thomas Healy and his crew are dancing a jig at their headquarters in Austin, Texas. EPA’s new emissions rule establishes the ERX Hypertruck know-how as at the very least a secure haven throughout the roll-out of the brand new guidelines, because it already exceeds the brand new NOx discount requirements.

Hyliion had invited me to Austin for a spin within the Hypertruck ERX again within the spring, however with scheduling conflicts, I lastly obtained there on the finish of November. (Full disclosure: Hyliion paid for my airfare and fed me a field lunch whereas I used to be in Austin.)

The truck I drove was a pre-production model of the ERX Hypertruck. I used to be instructed it’s higher than 90% manufacturing prepared.


Hyliion Founder and CEO Thomas Healy (left) gives HDT Equipment Editor Jim Park a walk-around tour of the ERX Hypertruck at the company’s corporate headquarters in Austin, Texas.  -  Photo: Hyliion

Hyliion Founder and CEO Thomas Healy (left) offers HDT Gear Editor Jim Park a walk-around tour of the ERX Hypertruck on the firm’s company headquarters in Austin, Texas.

Picture: Hyliion


ERX Hypertruck Defined

ERX is a totally electrical, battery-powered drivetrain saved charged by a natural-gas-powered generator, generally known as a spread extender. ERX is a major step towards decarbonization utilizing an power supply that’s already cleaner and cheaper than diesel. This answer affords basically limitless vary, and there’s no upfront infrastructure value, until a fleet needs to put in in-yard fueling services.

The truck has tandem drive axles, every powered by an independently managed electrical motor with a two-speed gearbox. The motor/gearbox meeting is mounted on the entrance of the differential housing the place we’d sometimes discover a driveshaft. The motors are powered by a pair of saddle-mounted batteries.

These batteries are charged by a Cummins ISX12N pure gasoline engine with no direct hyperlink to the drive axles. There’s an electrical generator mounted on the again of the engine the place the transmission often goes. The engine is fueled by 4 compressed pure gasoline storage tanks with a diesel-gallon equal capability of 175 gallons, which supplies the truck a spread of about 1,000 miles.


Natural gas stored in the back-of-cab storage tanks fuels the range extender engine, which charges the batteries. Batteries power the e-axle motors to drive the truck. The drivetrain is 100% electric.  -  Photo: Hyliion

Pure gasoline saved within the back-of-cab storage tanks fuels the vary extender engine, which fees the batteries. Batteries energy the e-axle motors to drive the truck. The drivetrain is 100% electrical.

Picture: Hyliion


Working solely on batteries, with the generator shut off, the truck has a spread of about 75 miles. That’s adequate to function in emissions abatement areas or at evening in areas the place noisy diesels are frowned upon.

The ERX powertrain is easy sufficient in idea, however fairly advanced in execution. There’s lots of calculating and computing happening within the background to take care of the optimum battery cost. Because the truck additionally takes benefit of regenerative braking, the engine-powered generator can stand down and let momentum cost the batteries when braking or descending grades.

It has a predictive charging system the place, by way of terrain mapping, the truck is aware of forward of time the place charging alternatives are and so will let the battery cost drop decrease than standard to seize as a lot free power as attainable when it may well. The system may be geofenced to make sure it solely operates in EV-mode at sure areas, equivalent to in cities, at warehouse services, and so forth. On this case, the system would mechanically maximize the battery cost to increase the EV-mode vary.  

What’s within the Field?

The truck I drove was an off-the-shelf Peterbilt Mannequin 579 — minus the normal driveline — with few apparent modifications to the cab or driver interface. As an alternative, the ERX powertrain options Meritor’s Blue Horizon 14Xe built-in e-axle drive axles as the usual place propulsion and regeneration {hardware}.

The Cummins ISX12N pure gasoline engine is mainly a inventory engine, however a lot of the accent drives, equivalent to the ability steering pump, air compressor and cooling followers, are all powered electrically off the battery so they’ll proceed operating when the engine is shut off in EV-mode.

The electrics demand little further upkeep, whereas the ISX12N requires the same old oil and spark plug adjustments at specified intervals. The truck additionally has an all-electric HVAC system that’s basically maintenance-free for idle-free and noise-free operation.


The powerplant of choice right now is Cummins’ ISX12G natural gas engine. Hyliion says when Cummins readies the  X15G  engine, it’s next under the hood.  -  Photo: Hyliion

The powerplant of selection proper now could be Cummins’ ISX12G pure gasoline engine. Hyliion says when Cummins readies the X15G engine, it’s subsequent below the hood.

Picture: Hyliion


The engine makes use of the usual maintenance-free three-way catalyst aftertreatment system discovered on different pure gasoline engines, and it already exceeds EPA’s newly printed low-NOx emissions customary. In case you are unaware, that’s 80% decrease than the present EPA customary for diesel engines.

The truck I drove had 4 compressed gasoline tanks (175 DGE) mounted behind the sleeper. That may be scaled again to a few or two tanks (65 DGE) to avoid wasting weight if vary isn’t an enormous concern.

There’s virtually no distinction from the motive force’s perspective. The cab and sprint format are the identical as a diesel Mannequin 579. The operate of the truck is similar, too. The acquainted shifter stick on the steering column is used to shift into ahead or reverse, and to regulate the extent of regen braking depth requested by the motive force, in a lot the identical means the shifter management is used on a diesel.

The truck had a prototype pill show mounted above the solar visor over the motive force to indicate the battery state of cost and different pertinent particulars in regards to the system. That pill will ultimately be built-in into an in-dash show with yet-to-be-determined performance. The driving force could have entry to some features of the charging system and battery-only operation however not all.  

Hyliion Founder and CEO Thomas Healy gave me a walk-around tour of the truck and accompanied me on the drive, giving me a number of alternative to ask questions. He answered most of them however was mum on a number of factors. In equity, it’s nonetheless in growth, so some specs would possibly change earlier than manufacturing begins.  

When requested about weight, he mentioned, coyly, “It’s lighter than a full BEV however heavier than a diesel.”

Driver Attraction

I’m afraid I don’t have something terribly thrilling to report right here; the ERX Hypertruck drives identical to every other Peterbilt 579, with a few exceptions. It’s actually quiet in within the cab, even with the vary extender engine operating. And with a complete of 670 hp on the wheels, it pulls higher than virtually any truck I’ve ever pushed.

We all know drivers aren’t keen on pure gasoline engines, however they love battery-electric vehicles for his or her energy and get-up-and-go. Right here’s the great thing about the ERX. In a typical driving situation, flat floor, open highway, the truck wants about 125 to 150 hp (like virtually any trendy aero truck) to take care of 65 mph or so. The pure gasoline engine pushes about 200 hp by way of the generator and into the batteries. There’s a optimistic stream of electrical energy to the batteries anytime the state of cost is between 50% and about 80%.

Nonetheless, if the motive force will get on the throttle for a climb or a passing maneuver, output isn’t restricted to the pure gasoline engine’s lame 400 hp/1,450 lb-ft, The driving force has a full 670 electrical hp and gobs of torque below foot. The depleted cost from that further push is well made up by the generator or regen braking alternatives.

When accelerating up a freeway onramp, as I did at one level, I may really feel the motors altering gears — although Thomas my co-pilot needed to level it out because it was taking place. As one of many two drive motors broke torque and shifted to excessive gear, the opposite motor saved powering the opposite drive axle. When the primary shift was full, the second motor/gearbox shifted to excessive gear, and we saved accelerating with no pause for the gear change. 

On the opposite finish of the electrical spectrum, regen braking was as robust or stronger than even a diesel engine brake. I used to be in a position to handle the depth of the braking (power seize) with management on the steering column, from place 1 (gentle) to place 3 (full). In a talented driver’s arms, this might simply be a one-pedal truck, with virtually no must ever contact the brake besides to carry the truck nonetheless at a site visitors gentle.

The in-cab noise stage in battery mode was about 10 decibels quieter than a diesel. The distinction is about the identical as a typical diesel at freeway pace in comparison with a reasonably good passenger automotive.

It was a bit louder with the generator engine operating, but it surely was much less obtrusive than a reefer engine. In truth, in some methods it was rather a lot like a reefer engine, biking on and off and altering pace with charging demand. The distinction was the sound was coming from the entrance moderately than behind the cab.

It was a bit odd accelerating and decelerating with no distinction within the sound of the engine. When it was operating, it ran at a reasonably fixed pace no matter what the truck was doing. However I feel most drivers would get used to that after a day or two of driving an ERX. 

Professionals and Cons of Pure Fuel

In some individuals’s eyes, pure gasoline remains to be a carbon-based fossil gasoline, and that’s sufficient of a purpose to sentence the stuff. Nonetheless, it’s cleaner-burning than diesel. It’s a lot cheaper; it requires a quite simple, no-touch aftertreatment system, and it already meets the ultra-low NOx and particulate matter (PM) requirements which might be inflicting consternation and gnashing of tooth between the engine makers and the regulators.

The U.S. Division of Power says burning 1,000,000 BTUs price of pure gasoline produces about 117 kilos of CO2, in comparison with 160 kilos for the same quantity (power content material) of diesel.

Additional, while you issue within the rising potential for renewable pure gasoline comprised of biomass, natural waste, manure ponds, and so forth., the emissions discount proposition turns into even higher.


Natural gas fuel is cleaner-burning than diesel. It’s much less expensive; it requires a very simple, no-touch aftertreatment system, and it already meets the ultra-low NOx and particulate matter (PM) standards  -  Photo: Hyliion

Pure gasoline gasoline is cleaner-burning than diesel. It’s a lot cheaper; it requires a quite simple, no-touch aftertreatment system, and it already meets the ultra-low NOx and particulate matter (PM) requirements

Picture: Hyliion


Chemically, RNG is almost similar to “pure gasoline.” Landfill gasoline and manure pond gasoline include potent types of methane and are better contributors to international warming than carbon dioxide, one of many byproducts of diesel gasoline combustion we’re making an attempt so laborious to curb.

By capturing and burning that methane as a gasoline to provide electrical energy, we not solely displace the CO2 produced by diesel gasoline when used to energy a truck, we additionally forestall the stronger methane from escaping into the ambiance. This permits renewable pure gasoline to be labeled as having a unfavourable carbon depth.

Hyliion makes an enormous deal out of utilizing RNG. That’s a bit disingenuous, I feel, until they’re tanking up at a devoted RNG producing facility. In fact, RNG is usually bought to pure gasoline distributors, the place it displaces a specific amount of fossil pure gasoline in these pipelines. Nonetheless, there are a lot of devoted sources of retail RNG. In California, for instance, greater than 90% of the pure gasoline consumed as a transportation gasoline is RNG.

The opposite large optimistic Hyliion’s ERX Hypertruck has going for it’s that it’s right here. Now. No ready a decade for the grid to catch as much as demand. No must improve truck terminals with high-voltage energy provides. And the fueling community is well-established alongside most busy truck corridors.

Hyliion accomplished its summer time testing a number of months in the past in Laughlin, Nevada. The testing and analysis crew is heading to Minnesota within the New Yr to conduct cold-weather testing. Hyliion is now doing managed fleet trials, and after evaluating fleet suggestions, it expects to start manufacturing of the ERX Hypertruck late in 2023 or early 2024.



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