Iveco Launches Electric Van with Cassette-Style Battery Swapping Technology
Iveco, the commercial vehicle manufacturer, has introduced a new electric van, the Iveco e-Daily, that showcases a unique use for cassette-style battery swapping technology. Unlike other battery-swapping systems that focus on roadside swaps for quick charging, the e-Daily allows users to remove or add elements to the modular battery pack, providing greater flexibility and adaptability.
The e-Daily offers three battery sizes – 37, 74, and 111kWh – which provide WLTP ranges of between 74 and 217 miles. This modular design allows users to choose the battery size that best suits their needs. For instance, if a van is used for last-mile delivery and does not require a long range, the smaller battery would be sufficient. This not only reduces costs and environmental impact but also increases the maximum payload by removing the weight of the battery.
However, if the vehicle’s usage changes and a longer range becomes necessary, the battery can be taken to an Iveco service station, where the cell count can be increased to 74 or 110kWh. Similarly, cell packs can be removed and swapped between vehicles in a fleet as needed.
While the process of swapping a battery pack takes around two hours and must be done at an Iveco service center, this system provides fleets with the flexibility of range and resources. The cost of a new cell pack is approximately £15,000, plus labor costs. Iveco also offers discounts in exchange for old packs, depending on their age and condition.
The battery pack technology used in the e-Daily is provided by Chinese manufacturer Microvast. It utilizes a nickel-manganese-cobalt lithium-ion cell chemistry similar to that found in many modern EVs. The modular packs can be easily slotted in and out of the Iveco chassis, providing ease of use and maintenance. The battery packs come with a warranty of 155,000 miles and eight years, with a performance guarantee of 80%, regardless of the frequency of 80kW DC rapid charging.
Iveco’s ladder-frame chassis is perfectly designed for modularity, not only for electric vehicles but also for future adaptations to hydrogen technology. Iveco has partnered with Hyundai on hydrogen and other future projects, showcasing Hyundai’s fuel cell technology in Iveco van and bus concepts. However, there are no plans to license the modular battery technology to other companies at this time.
The benefits of battery swapping technology extend beyond the flexibility it provides for range and resources. Modular batteries allow for right-sizing of the battery, reducing the use of critical materials in lower-duty applications and maximizing performance when needed. Additionally, the ease of removing batteries allows for easier recycling or reuse. Iveco plans to offer second-hand batteries back to customers as a more affordable option, extending the life of the batteries before repurposing them for stationary energy storage or recycling.
While Iveco may be the first company to bring this type of battery-swapping technology to mass production in Europe, others have also recognized the potential of modular batteries. Chinese electric car maker Nio has pioneered roadside battery swaps in China, and battery manufacturing giant CATL has recently announced a module-to-bracket system for trucks and construction machinery.
In conclusion, Iveco’s e-Daily electric van with cassette-style battery swapping technology offers a unique solution for commercial vehicle fleets. The ability to retrospectively remove or add elements to the modular battery pack provides flexibility and adaptability, allowing users to choose the battery size that best suits their needs. This technology not only reduces costs and environmental impact but also extends the life of the batteries through recycling and reuse. As battery swapping technology continues to evolve, it has the potential to revolutionize the electric vehicle industry by addressing range anxiety and improving charging infrastructure.