Energy recovery downhill: How recuperation extends the range of electric commercial vehicles in the mountains

Driving in the mountains is a challenge for any vehicle, especially uphill. However, electric commercial vehicles offer a decisive advantage when going downhill again: recuperation. This technology converts kinetic energy into electrical energy and feeds it back into the battery. This extends the range and makes driving in alpine terrain more efficient and sustainable.

What is recuperation and how does it work?

Recuperation, also known as regenerative braking, is a process in which the electric motor of a vehicle acts as a generator. When the accelerator pedal is released or the brakes are applied, the motor is no longer supplied with electricity. Instead, it is driven by the kinetic energy of the rolling vehicle, generating electricity that flows back into the battery.

More information can be found in this blog article: Recuperation in electric vehicles: Efficient energy recovery.

Why is recuperation particularly important in the Swiss mountains?

Recuperation really comes into its own in the Swiss mountains. Why? Because long and steep downhill stretches provide ample opportunity to recover energy. Gravity helps to propel the vehicle, while the engine acts as a brake and charges the battery at the same time.

After a strenuous uphill ride that has consumed a lot of energy, you can recover some of this energy on the descent. This is a decisive difference to diesel-powered vehicles, which destroy energy by simply braking (and therefore heat) on the way downhill. E-commercial vehicles use this potential energy efficiently.

Although the challenging topographical conditions in Switzerland put vehicle batteries under pressure, they also offer enormous potential for energy recovery. Steep climbs and downhill stretches put intense strain on batteries, which is why efficient thermal management systems are essential.

Recuperation in electric commercial vehicles: the special challenges and advantages

E-commercial vehicles are often heavier and have more powerful engines than
passenger cars. This has a particular impact on recuperation:

• Higher potential: More mass means more kinetic energy,
  which can be converted into electrical energy when driving downhill.
  A heavy e-transporter can potentially recover more energy
  than a lighter vehicle.

• Robust systems required: The recuperation system must be robust
  enough to safely process higher amounts of energy and feed it into the
  battery.

• Thermal management: The recovery of braking energy generates
  heat, which modern systems use to preheat batteries or heat the vehicle cabin.

While ADAC tests have shown efficiency values of 35% to over 50% for passenger cars, the potential for heavier commercial vehicles can be even higher, depending on the topography and driving style. This is particularly relevant for delivery services, municipalities or tradesmen who are often on the road in hilly or mountainous terrain.

Practical success stories from Switzerland

Switzerland is already showing impressive practical examples of the successful use of recuperation technology:

DPD Switzerland and Futuricum

DPD Switzerland operates the Futuricum Logistics 18E, an electric truck with a 680 kWh battery that enables a range of up to 760 kilometers. This model impressively demonstrates how advanced recuperation systems recover energy from braking processes, thereby significantly extending the operating range and reducing operating costs.

Flux Mobility - Swiss innovation for alpine challenges

As a Swiss pioneer, Flux Mobility develops electric commercial vehicles specially tailored to the requirements of the Alpine regions. By using a specially developed, fully electric all-wheel drive, our vehicles meet the high requirements for traction and stability in mountainous terrain. The vehicles have a range of up to 320 kilometers and can transport loads of over 1,000 kg - a realistic alternative to conventional diesel models.

The integration of recuperation plays a central role in increasing energy efficiency and maximizing vehicle range on challenging routes. Our successful collaboration with emergency services proves the practicality of this in alpine and urban scenarios.

Innovative pilot projects

Swiss Post has launched a vehicle-to-grid (V2G) pilot with light electric vehicles, whereby bidirectional charging processes for grid stabilization enable the intelligent use of electricity flows. These projects are part of the National Roadmap for Electric Mobility 2025 and provide important data for optimizing recuperation strategies in practice.

Practical tips for optimum recuperation in the mountains

To make optimum use of recuperation and maximize your range, there are a few things you should bear in mind:

• Drive with foresight: Recognize slopes early and release the accelerator pedal to start recuperation. Avoid braking hard with the mechanical brake wherever possible. 
• Select recuperation level: Many e-commercial vehicles offer
  different levels of recuperation. Use a
  higher level on steep descents to recover more energy and protect the service brake.
• Consistent speed: A consistent downhill speed enables continuous energy recovery. Frequent acceleration and braking is less efficient.
• Pay attention to thermal management: The batteries work less efficiently at cold temperatures, so it is advisable to preheat the battery before setting off.

Used correctly, recuperation can not only extend the range, but also reduce wear on the brakes and lower overall operating costs.

Technological innovations and future trends

The latest generation of electric commercial vehicles integrates advanced recuperation systems that not only improve energy efficiency but also extend battery life. These systems use predictive analytics to ensure optimum recovery of braking energy.

One innovative example is integrated brake chopper resistors (iBCR), which convert excess energy into heat that can be used to preheat batteries or vehicle cabins. This supports improved thermal management and reduces energy losses.

Future developments will focus on:

• Solid-state batteries: Higher energy density and improved safety
• Intelligent charging infrastructure: dynamic adaptation to electricity prices and available renewable energy
• Modular vehicle platforms: Combination of different drive technologies for flexible solutions

Economic and ecological advantages

The practical effect of recuperation in the Swiss mountains is a noticeable increase in range. Instead of simply losing the energy consumed when driving uphill, a significant proportion of it is fed back into the battery. This means for operators of electric commercial vehicle fleets in mountainous regions:

• Fewer charging breaks: the vehicles can travel longer distances before they need to be recharged

• Lower operating costs: more efficient energy use leads to lower power consumption per kilometer driven

• Increased operational capability: vehicles are available for their actual tasks for longer

• Reduced maintenance costs: less wear on the mechanical brakes

The economic impact goes beyond direct cost savings: the growing demand for electromobility is stimulating a convergence of traditional automotive and manufacturing industries towards clean technology, creating new value chains.

Overcoming challenges - moving forward together

Despite all the progress made, there are still challenges to overcome. The availability of charging infrastructure in remote Alpine regions is still a limiting factor. A lack of or insufficient fast charging stations makes it difficult to operate e-vehicles in these areas in line with demand.

However, Switzerland is working hard to overcome these barriers. The expansion of an efficient charging infrastructure, in particular fast charging systems along central transport axes, is intended to promote the spread of electric commercial vehicles and drive forward the decarbonization of transport.

Conclusion: The future is electric uphill and downhill

Energy recovery through recuperation is a key technology that predestines electric commercial vehicles for use in the Swiss mountains. It transforms the challenge of steep descents into an opportunity to increase efficiency and extend range.

For companies and municipalities that rely on sustainable and economical transportation solutions in alpine regions, recuperation is an important factor when choosing the right vehicle. It enables electric commercial vehicles to outperform diesel-powered alternatives not only in terms of emissions, but also in terms of operational efficiency in challenging terrain.

Modern electric commercial vehicles, designed for performance and efficiency, make recuperation a powerful tool for sustainable mobility - especially where there are uphill and downhill stretches. The combination of innovative technology, regional expertise and partnership-based support creates the basis for the successful electrification of your fleet.

Ready for the electric future in the mountains?

Would you like to find out more about the possibilities of recuperation for your vehicle fleet? Our experts at Flux Mobility will be happy to help you find the right solution for your specific requirements.

Contact us today for a no-obligation consultation and discover how e-commercial vehicles with advanced recuperation technology can boost your business.