Truck & Off-Highway Engineering - October 2022 - 11

TECHNICAL INNOVATIONS
the vehicle frame to package the battery
systems, " Weicker explained.
Harbinger's Class 4 to Class 7 EV
platform will use an 800-volt, liquidcooled
battery system that is scalable in
35-kWh increments. " By allowing customers
to select the battery capacity
that works best for them, we are able to
offer them the most economical solution
that meets their needs while maintaining
the advantages of a common
platform, " Weicker said.
Aluminum parts will be integral to the
battery packs. " The recent availability of
large format die-cast aluminum components
gives us great flexibility in designing
a cost-effective battery system that
will withstand the rigorous environment
in which we expect our vehicles to operate, "
Weicker said. He noted that conventional
multi-piece sheet metal construction
techniques used for light-duty
passenger vehicles would not meet
Harbinger's best-in-class lifetime targets.
With a step-in height below 28 in. (711
mm), that best-in-class target meant
overcoming numerous engineering challenges.
To achieve desired ground clearance,
breakover, approach and departure
angles, an alternative to a traditional
constant-section frame rail was needed.
" The use of an all-new fully forged steel
crossmember over the rear axle, combined
with variable section roll forming
used to create our high-strength-steel
frame rails, allows us to reduce the
frame's section height to accommodate
the rear axle, " Weicker said. In the front,
the use of forgings provides the ability to
incorporate an industry-first mediumduty
truck independent front suspension
with the packaging requirements of a leaf
spring and steel solid front axle.
Harbinger's next step for mediumduty
EVs involves various proving
ground tests, including road gradients
up to 32 degrees, full payload and trailer
tow, winter-weather drives with lowfriction
surfaces (such as ice and snow)
and hot-climate uphill grade towing.
Powertrain and battery durability testing
is also in the mix.
ElectroForge, a joint venture involving
Harbinger Motors Inc. and Kalyani
Powertrain Limited (a wholly owned
TRUCK & OFF-HIGHWAY ENGINEERING
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October 2022 11
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subsidiary of Bharat Forge Ltd, India's
largest automotive forging company),
will put the drivetrain on a course toward
high-volume production. " The
joint venture is our manufacturing and
commercialization effort for the powertrain
specifically, " said Harbinger's
CEO, John Harris. High-volume production
is targeted to begin in late 2024 or
early 2025, with low-volume production
prior to that timeframe.
Kami Buchholz
http://info.hotims.com/82346-707
Truck & Off-Highway Engineering - October 2022

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