Smart trailers making things safer?

The trucking industry is discovering that electrified trailers (eTrailers) offer more than just fuel savings and environmental benefits… JACO DE KLERK reports.

Range Energy, a company specialising in trailer electrification technology, has completed vehicle dynamics and stability testing for its eTrailer system at the Transportation Research Center. The results – generated at one of North America’s most advanced independent mobility testing facilities – show that eTrailers can actively enhance safety in ways conventional trailers simply cannot.

These trials followed earlier winter testing conducted in March in northern Michigan, where engineers evaluated performance on ice and snow. The system improved braking distances and prevented the trailer from swinging sideways on slippery, icy roads.

“Our recent winter testing confirmed that Range’s system significantly enhances safety and performance under adverse conditions. We can assist the tractor in both acceleration and braking when traction is limited, and control the combination more predictably than a traditional trailer,” says Ali Javidan, CTO and founder of Range Energy. “We’re pleased with the driver feedback we’ve received on the system – it increases predictability, helps when traction is limited, and makes driving a truck and trailer in extreme conditions feel easier and safer. One of our main goals is to support driver confidence with our advanced system, while reducing the needed trailer modifications.”

The 2025 summer programme focused on validating the system’s performance under challenging driving scenarios. On dry pavement surfaces, the risk of trailer rollover increases, so these were specifically targeted. The company fitted its trailer with protective devices to prevent rollovers during rigorous manoeuvres – including J-turns and double lane changes – and evaluated traction control during straight-line acceleration and braking.

More than 400 dynamic manoeuvres were performed across varying speeds, payloads, and tractor configurations to ensure the electrified system integrates seamlessly with standard truck braking and stability systems. The same tests were repeated on wet surfaces to provide comprehensive data across differing road conditions.

A key finding revealed a crucial safety advantage: compared with conventional trailers, the Range system triggered regenerative braking (which captures energy while slowing down) earlier during critical manoeuvres. This gently reduced speed and cut the pushing force that can tip a trailer by up to 25%. In practice, that allows drivers to complete the same turn at the same speed more safely, helping to avoid loss of control or rollover.

“Testing under extreme conditions and with aggressive manoeuvres is critical to prove the intelligence and reliability of our control systems in real-world conditions,” says Kyle Foley, head of engineering at Range Energy. “From fine-tuning traction control and delivering precise stability interventions through regenerative braking, to ensuring seamless compatibility with today’s truck brake systems, every element is designed to perform when it matters most.”

Importantly, Range’s system is designed to work with a wide variety of trucks – both diesel and battery-electric – without requiring any modification to the tow vehicle.

These safety benefits build on the efficiency improvements we reported in our third issue last year. Earlier testing by Mesilla Valley Transportation Solutions (MVTS) – a company providing breakthrough testing, design, and development services for the trucking industry – demonstrated that Range’s technology can deliver up to 36.9% fuel-efficiency improvements for semi-trucks. Testing was conducted on a 41-km route at highway speeds, carrying nearly 27 tonnes of payload across multiple scenarios.

“We were impressed with the Range trailer. Whether a fleet wants to reduce fuel usage or increase battery-electric vehicles’ range, this system provides unique opportunities over a traditional trailer – and by a large amount, given it achieved 36.3% fuel savings,” says Daryl Bear, COO of MVT Solutions. “Our drivers also liked the Range trailer, reporting it pulled easier and felt lighter.”

As the trucking business evolves, electrified trailers are proving that they offer more than environmental gains alone. Intelligent regenerative braking systems that actively influence vehicle dynamics represent a significant step forward in commercial vehicle safety. We’ll keep you posted as the story continues to unfold.