@NACV: Big E-News From Dana

Dana got the North American Commercial Vehicle show off to a big start, by announcing several moves in its electrification business.

First, in collaboration with Lonestar Specialty Vehicles, Dana announced the launch of a fully electrified terminal tractor. The new Spicer Electrified e-Powertrain system is designed and manufactured by Dana as a complete electric powertrain solution for use on vehicles built by Lonestar SV (shown above).

Lonestar SV, founded in 2014, specializes in the final stage assembly and refurbishment of commercial vehicles and other vehicle application solutions. Dana’s e-Powertrain system can be adapted by Lonestar SV into a vehicle with a non-powered rolling chassis, or existing vehicles with diesel engines can be converted into all-electric trucks.

“Utilizing our recognized strength in the development of complete battery-electric vehicle systems, Dana engineered the electric powertrain from the ground up,” said Mark Wallace, president of Dana Commercial Vehicle Driveline Technologies. “This competency, augmented with Lonestar’s extensive vehicle assembly and refurbishing experience, provides fleets the ability to immediately outfit terminal tractors with complete electrified systems for reduced emissions and increased operating efficiencies.”

The powertrain provided by Dana includes the motor, inverter, power electronics cradle, and battery systems. The collaboration also includes full vehicle integration education and training from the Dana team, allowing Lonestar SV to complete the vehicle integration in-house.

The Lonestar vehicle has a gross combination weight rating (GCWR) of 80,000 or 101,000 lb. and is offered in 4 x 2, 6 x 2 and 6×4 configurations. The electrified system can be customized to meet individual range requirements, Dana said. The Lonestar SV T22 and S22 models allow for 22 hours of continuous operation with only two hours required for a full battery recharge. The T12 and S12 models allow for 12 hours of continuous operation and are equipped with DC fast-charging capability.

Dana also said it will partner with “a major North American commercial vehicle manufacturer” to supply complete e-Powertrain systems for a medium-duty vehicle program beginning next year. The new trucks will feature Dana’s Spicer Electrified powertrain technologies and are expected to be on the road in early 2021.

Separately, Dana said it also secured a new e-Powertrain development project with another “leading truck manufacturer.”

The company announced a medium-duty vehicle program, consisting of a complete electric powertrain system that is fully designed, integrated, and upfitted to the customer’s chassis by Dana. The three-year program is expected to generate approximately $200 million in incremental sales to Dana, with vehicles available for order from the manufacturer in the second half of 2020.

Dana’s e-Powertrain system can be adapted by Lonestar SV into a vehicle with a non-powered rolling chassis, or existing vehicles with diesel engines can be converted into all-electric trucks.

Configured as a direct drive system, which uses a motor to power a Dana- provided axle and driveshaft, the trucks will feature Dana’s complete e-Powertrain system, which consists of:

– A Spicer Electrified e-Propulsion system, comprising a Dana TM4 motor and inverter.

– A Spicer Electrified e-Power system, which generates, stores, and manages the energy for the vehicle. This system consists of the battery packs, battery management system, on-board charger, power electronics cradle and electrified auxiliary systems.

– Dana-developed software and controls that will enable the diagnostics and telemetry of the system, as well as thermal management.

Dana is partnering with a second truck manufacturer on an electrified vehicle development platform that will incorporate a Dana TM4 SUMO HP motor that was purposely developed for both hybrid and battery electric configurations.

“The recent acquisition of Nordresa, a recognized leader in electric commercial vehicle integration, serves as an enabler for Dana to expand the development and integration of clean, electric powertrains to deliver higher efficiency and lower cost of ownership,” said Wallace. “These new vehicle programs leverage Dana’s complete e-Powertrain products and capabilities, while demonstrating our ability to deliver end-to-end turnkey electric systems for our customers, which will, in turn, provide Dana profitable growth through electrified system sales.”

To date, Dana said its e-Propulsion technologies have been used on more than 16,000 commercial vehicles globally and have been driven more than 600 million miles.

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