The modular toolbox that lets you design the optimal BEV

Tailor-made solutions, unmatched flexibility, and rapid integration of new technology – these are just some of the advantages Scania’s modular system offers our customers. Refined over decades, Scania’s legendary toolbox now takes the next step, adapting to the new era of electrification.

There are two ways to design an optimal truck – a truck that’s tailored precisely to the transport tasks you usually perform. One approach is to design every component, including its placement on the vehicle, entirely based on that individual specification.

A truck like that would be quite expensive – and probably not very service-friendly.

The other way is to develop a modular toolbox – a vast construction kit where every piece fits – using as many shared components as possible to create a wide range of customer-specific variants.

A truck built from such modules is more cost-efficient, more flexible – and just as tailor-made.

Modular system successful for customers

About half a century ago, Scania chose the second path – a decision that has proven enormously successful, both for the company and for its customers. And now, it’s time to take the construction kit – Scania’s famous toolbox – into the electrified future.

"Many components – such as frames, cabs, and axles – are the same for both ICE and BEV trucks," says Mats Holmstrand, Product Planning Manager at Scania e-Mobility.

“Thanks to Scania’s extensive experience in building internal combustion engine vehicles using our modular toolbox, we were able to develop and design a battery electric truck quicker than if we had started from scratch,” he says.

“The basic idea – to construct optimal vehicles from as few parts as possible – is the same whether we’re building battery electric trucks or combustion engine powertrains,” Holmstrand adds.

A closer look at the modules in a BEV

However, there are of course new elements in the construction kit when building a BEV. Let’s take a closer look at some of those components:

Batteries. Thanks to the modular approach, Scania’s battery packs can be combined and installed in a number of ways to best fit the application. We offer three different options for battery packs: two for frame installation, and one that is fitted underneath the cab. These can be combined in four different ways, from 416 kWh to 728 kWh installed capacity.

Electric machine. A crucial building block when putting together a BEV is of course the electric machine. Scania currently offers three different e-machines, ranging from 210 to 450 kW continuous power. Whereas an ICE engine is mounted at the front of the truck, the BEV equivalent – the electric machine – is placed centrally in the chassis, slightly further back than an ICE engine.

In addition to the existing setup, Scania is also developing a solution where the electric machine integrated directly onto the axle, combining the electric motor, power electronics, and gearbox into a single unit that powers the wheels directly.

“This new solution won’t replace Scania’s current electric powertrain architecture, but rather complement it – providing additional flexibility for different applications and operational needs,” says Holmstrand.

Charging interface. Scania’s BEVs currently use CCS2 connectors, supporting up to 375 kW of charging power. Thanks to the use of common components, Scania’s BEVs can easily be fitted with additional connectors – for example, at the rear of the vehicle to better facilitate depot charging.

“We are also preparing a connector ‘module’ for the upcoming ultra-fast Megawatt Charging System (MCS),” says Holmstrand. “MCS will enable ultra-fast charging suitable for long-haul BEV operations, drastically reducing downtime. Depending on the application, some BEVs will likely be equipped with two charging interfaces: CCS2 and MCS.”

Services and software. As well as for vehicles and hardware, Scania also applies its modular approach to the design of services and software. An example is how the entire process of the electric powertrains is managed and controlled by the vehicle’s electronic control unit (ECU) and the Battery Management System (BMS). These systems monitor and optimise various parameters such as battery temperature, state of charge, and power distribution to ensure efficient and safe operation.

“The modular system is in our DNA”

Mats Holmstrand says that as electrification advances, Scania’s modular approach will continue to ensure that customers get the right solution for their transport challenges – now and in the future.

“It’s in every Scania engineer’s DNA to make the most of the modular system – and to keep developing smart, resource-efficient, and tailor-made solutions,” he says.

Scania’s modular system in short

The first steps to create Scania’s much-admired toolbox, the modular product system, were taken already in the 1960’s.
Today, Scania’s entire product portfolio is based on a modular design composed of a fixed number of standardised interfaces, allowing for components and parts to be interchanged. This allows the company to optimise our solutions quickly and easily for specific customer needs, applications and markets.
Modularisation creates a lean and flexible production system that allows Scania to introduce new technologies rapidly, bring them to market – and scale them up – quickly.