Range anxiety - the fear that an electric vehicle (EV) will run out of charge before reaching its destination - is a common reason cited by fleets for operating EVs conservatively or not deploying them at all. EV range is influenced by several factors - temperature, terrain, traffic conditions, cargo weight, driving efficiency, etc. In our last article, we explored the effects that temperature can have on EV fleet operations. In this article, we will dig deeper into the effects that cargo weight can have on range, what that means for fleets, and how they can manage it.

What is the effect of cargo weight on range?

Vehicle manufacturers (OEMs) typically report range as a single value or a limited set of values if they offer models with varying battery pack sizes. The way that OEMs report range varies slightly from one to the next, but often it is reported as a maximum achievable mileage under lightweight or no cargo load conditions. Some OEMs, however, will report range assuming some payload or extra weight on the vehicle. For example, the range analysis for the BrightDrop EV600 was reportedly completed at half payload capacity. This lack of standardization for range calculation can create uncertainty about how much range EVs can actually achieve under real-world conditions.

As medium- and heavy-duty (MHD) commercial EV deployments are still relatively new, literature that specifically addresses the effects of cargo weight on their range is limited. However, we can draw on a handful of articles, demonstrations, and reports that have discussed the topic for EVs in general.

The general industry consensus is that an increase in cargo weight leads to a marked decrease in range. However, the extent to which range is impacted by cargo weight varies. 

The most readily available data is for light-duty electric pickup trucks which indicates that payloads over 3,000 pounds (about 35% of the F-150 Lightning Platinum’s gross vehicle weight) can decrease range by 60-70%.

What’s more, it has been reported that as an EV’s battery gets closer to full depletion, the amount of power delivered to its motor may decrease. That means less power available to move the same cargo load compared to a situation in which the EV has a higher battery state of charge.

Some MHD fleets have already started to test this for themselves, such as PepsiCo and Anheuser-Busch. One of PepsiCo’s Vice Presidents was recently quoted saying “PepsiCo’s new [Tesla] Semis can haul Frito-Lay food products for around 425 miles, but for heavier loads of sodas, the trucks will do shorter trips of around 100 miles.” However, PepsiCo also hopes to use the Semis to haul beverages in the “400 to 500 mile range” in the future as well.

How can fleets manage this?

Plan ahead – know your routes and duty cycles well before deciding which EVs to procure and operate, and choose vehicles wisely. As you begin operating EVs, monitor how range fluctuates under different conditions – varying temperatures, cargo weight, drivers, etc. Use this knowledge to make informed decisions for any operational adjustments. For example, if you expect to haul a heavy load on a day that is particularly cold, expect your range to be lower than usual and plan accordingly.

Train drivers and incentivize efficient driving – driving an EV is a different experience than driving an ICE vehicle, and driver performance is significantly correlated with the EV’s efficiency. Things like hard acceleration and hard braking can worsen efficiency, but they are preventable. As you deploy EVs, don’t forget to also train your drivers so they will be prepared to operate this new equipment. Also, consider developing a driver incentive or rewards program to encourage efficient driving.

Seek help from intelligent fleet management systems – As stated previously, several factors affect EV range, not just cargo weight. Accurately predicting EV range requires fleets to take all of these factors into account simultaneously. This can be difficult to do without the help of intelligent fleet management systems that can collect, monitor, and analyze your operations data. Seek out the help of these systems and use them as tools to equip you with the insights you need to better manage your EV operations.