Development and Demonstration of a Class 6 Range-Extended Electric Vehicle for Commercial Pickup and Delivery Operation

Michael Kader, Cole Frazier, John Kresse, Ke Li, Jesse Dalton, Matthew Jeffers, Eric Miller, Kenneth Kelly

Research output: Contribution to conferencePaperpeer-review

3 Scopus Citations


Range-extended hybrids are an attractive option for medium- A nd heavy-duty commercial vehicle fleets because they offer the efficiency of an electrified powertrain with the driving range of a conventional diesel powertrain. The vehicle essentially operates as if it was purely electric for most trips, while ensuring that all commercial routes can be completed in any weather conditions or geographic terrain. Fuel use and point-source emissions can be significantly reduced, and in some cases eliminated, as many shorter routes can be fully electrified with this architecture. Under a U.S. Department of Energy (DOE)-funded project for Medium- A nd Heavy-Duty Vehicle Powertrain Electrification, Cummins has developed a plug-in hybrid electric Class 6 truck with a range-extending engine designed for pickup and delivery application. The National Renewable Energy Laboratory (NREL) assisted by developing representative workday drive cycles for Class 6 operation and an adapted cycle to enable vehicle track testing. A novel, automated driving system was utilized by Southwest Research Institute (SwRI) to improve the repeatability of the track testing conducted to quantify vehicle energy consumption. Cummins used a drivetrain model to design the hybrid control system for increased fuel savings. The control system functionality and fuel savings objective of 50% or more were confirmed by track testing described in this paper.

Original languageAmerican English
Number of pages7
StatePublished - 14 Apr 2020
EventSAE 2020 World Congress Experience, WCX 2020 - Detroit, United States
Duration: 21 Apr 202023 Apr 2020


ConferenceSAE 2020 World Congress Experience, WCX 2020
Country/TerritoryUnited States

Bibliographical note

See NREL/CP-5400-78181 for preprint

NREL Publication Number

  • NREL/CP-5400-75847

Other Report Number

  • SAE Technical Paper No. 2020-01-0848


  • class 6 range extender
  • commercial electric vehicles
  • electric vehicle
  • heavy-duty vehicle
  • medium-duty vehicle
  • range-extended hybrid electric vehicle


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