How FutureMotiv helped remove a Truckload of CO2 emissions

According to Statista, Heavy Commercial Vehicles in the UK emitted 18.6 million metric tons of CO2 equivalent. Although this value was the lowest recorded since records began, this class of vehicle is still the second-largest contributors to UK transport emissions – behind passenger vehicles. 

Consequently, to reach the government’s Net Zero targets, low and zero carbon emissions Heavy Commercial Vehicles will play a vital role. 

When FutureMotiv was approached by an electric truck startup, therefore, we understood how important our work could become to make a real impact – not just here in the UK, but globally.

FutureMotiv, part of RLE International, were tasked to deliver all electrical systems within a fully electric truck. We were uniquely suited for the assignment as we had expertise in 3 key areas specific to this:

1.      Expertise in vehicle electronics

2.      In-depth knowledge of high voltage systems

3.      Understanding throughout the business of truck mechanics and systems

We were able to join the project when our client was a company of just 20 people. That meant we were the project leaders from the very start – and were entrusted to establish the department. However, as is the case working with any start-up business, the company grew as the project progressed.

Our core design strategy allowed us to integrate with the new members of staff, get them up to speed on the project, and continue the accelerated momentum we had established.

As key developers of the project’s functional safety, it was imperative to establish confidence in the product so the final vehicle rolls off the production line with no unforeseen problems. Part of this was to identify all potential malfunctions that could exist in an electric truck, providing a failsafe for every single one.

Building a traditional heavy commercial vehicle would have brought its own challenges, but this project had been designed in a totally inimitable way.

Part of the challenge was down to driving position. The final design for this product incorporated a central driving position, and not the left-hand or right-hand drive structure we are all familiar with. The central driving position meant traditional electronic systems needed to be redesigned. Moreover, since this vehicle has forgone conventional wingmirrors for cameras and screens, we had to create an electrical system that is robust enough to maintain the safety of drivers and other road users.

Below the surface, FutureMotiv designed and built electrical systems for the vehicle’s power steering, its brakes, even the tailgate for the loading area.

The functional safety was of further importance given this product was intended for use in populated urban areas. Providing electrical systems to the final production teams which were guaranteed to be safe had to be the ultimate goal.

Achieving what we did for this project is truly a testament to the whole FutureMotiv team. Many went above and beyond the call of duty to get this done not only safely, but incredibly swiftly.

Although there was no explicit knowledge of building a battery EV Heavy Commercial Vehicle, indeed there were no existing examples from which to reference at this point, our engineers were capable of drawing from knowledge of previous experience. This gave FutureMotiv the agility that is sought after by startups to provide tangible results in a short timeframe.

It took 7 months to build a Mule Vehicle (working prototype), from a mere germ of an idea. A feat, in the words of our Managing Director, that was “absolutely astonishing”.

Following the first Mule Vehicle, we embarked upon the ‘Design Validation’ (DV). This is the elevated level from a Mule, which is built to prove the base functionality, and incorporates much more of the final design. By December 2021, two of these DV vehicles were completed – five months after the Mule was completed.

None of this would have been possible if it were not for the collective effort of the FutureMotiv team. We were able to move with agility, sharing our breadth of knowledge between teams, and built a firm trust with the client, enabling us to drive the project to its conclusion rapidly and skilfully.

If you have an automotive design concept and require a team with a proven track record of achieving results in a time limit, then do get in touch to discuss your project.