Transport vehicle fleets rely on constant operational readiness if they want to work economically. Axle and chassis manufacturer BPW knows how to avoid unforeseen damages and downtimes. For example, with the iC Plus trailer chassis in combination with the software solution from its subsidiary Idem Telematics. The iC Plus Retrofit retrofitting solution was also presented at this year's Conference Days.
What causes trailer downtime?
“In transport, there is actually nothing more expensive than a vehicle that is in the workshop, breaks down on the roadside, accumulates fines due to lack of maintenance, or, in the worst case, causes an accident,”
introduced BPW product manager Caren Freudenberg in her presentation. The reasons can be attributed to several factors such as insufficient air pressure in the trailer tires, which are heavily stressed by different load weights and road conditions. The pressure difference accelerates tire wear and can potentially become a traffic risk. In any case, according to Freudenberg, tire breakdowns accounted for the most common cause of failures, with two-thirds.
Decreasing braking performance can also affect the operation of vehicles to the point of a standstill. And finally, the prescribed maintenance cycles and inspections also keep vehicles from operating.
Potential Savings
The suspension expert sees countermeasures in targeted maintenance planning, which can increasingly be accomplished with intelligent algorithms. BPW, for example, can already quite accurately capture the condition of trailers, issue warnings, and initiate maintenance measures in advance, also known as Predictive Maintenance.
Freudenberg explained the solutions using specific functions for the latest, first introduced in 2023 "digital" axle iC Plus. For example, the Brake Performance Monitor solution displays the braking condition based on the data captured with the axle. Thus, the brake can be selectively optimized through continuous monitoring. This is done using integrated sensors that monitor the wear of the brake pads.
The axle load display also provides comprehensive data: this time about the loading. The values are then displayed in the telematics system from Idem Telematics. Through monitoring, it is ensured that there is no overload. And the
monitoring goes even further: it can almost in real-time determine when the vehicle has been loaded and unloaded. Under what conditions a warning should be issued can be individually configured.
One of the main points, however, still represents the tire pressure monitoring, which is legally required for new commercial vehicles from July 2024 under UN ECE R 141. The iC Plus chassis generation can now not only be equipped with the Tire Pressure Monitoring System (TPMS) but also with a Tire Pressure Regulating System (TPRS), which keeps the pressure always in the optimal range. BPW calls this AirSave tire pressure regulating system.
Important: TPMS System
Here, the advantage of the iC Plus chassis shows: Normally, the prescribed air pressure control system TPMS must be connected to the Electronic Brake System (EBS) with an additional device. With iC Plus, this additional component is unnecessary since the TPMS or, as a comfort system, also the AirSave sensors can be used for this. The sensors are networked with the telematics so that fleet managers can keep track of data at any time via the Cargofleet telematics platform.
BPW promotes its AirSave System with significant fuel savings and reduced tire wear and promises savings of up to 890 euros and 655 kilograms of CO2 per year.
Additionally, BPW has developed a digital maintenance calendar for the Cargofleet Portal to ease managers' planning of workshop visits and also contains the maintenance history, for example.
Scope of iC Plus
The standard BPW axle with its regular 9 t unit and optionally ECO Air or Airlight II suspension as well as disc or drum brakes, is transformed into an iC Plus axle through specific functional additions. For example, by including a brake pad wear sensor available for both brake types. The package of components that upgrade the axle to an iC Plus component also includes a connection for all common EBS. The package also includes the basic telematics equipment for trucks and vehicle fleets in the Basic or Pro version: the so-called TC Trailer Gateway enables
entry into telematics and offers a modular, flexibly expandable modular system for data capture solutions. Access to the Cargofleet 3 portal is also included. Optionally, TPMS or TPRS (AirSave) can be added.
Cargofleet Telematics Portal: Intelligent Maintenance
The telematics platform, through which the captured data can be viewed and evaluated, was introduced by expert Heiko Boch, Head of Product Management at Idem Telematics.
The end device is installed in the trailer, as already known from the truck, and captures vehicle data. The vehicle is localized via GPS. All information is captured at the headquarters via the classic mobile communications system, where the states can be evaluated and displayed clearly via Cargofleet. In this way, freight forwarders have all data about the vehicle condition and the location of the trailers in view at any time. “With trailer telematics, we have continuous monitoring,” said Boch.
The Cargofleet portal can then also be used for individual alarm outputs - for example, it can be set who should be informed under what circumstances (e.g., temperature exceedance) via what means (email, SMS, etc.). Reports are also created according to various parameters. Maintenance information can also be included for individual planning. Boch:
“After maintenance has been carried out, the result can be documented, so the circle closes: the maintenance cycle starts anew, and I have continuous documentation of my maintenance on the vehicle.”
According to Boch, the application is usable across brands via open interfaces. “We integrate other systems.” Regardless of vehicle types – trailers, trucks, or others – the systems are integrable and can also input trailer telematics data into other systems. “We have no qualms with competitors.” The question is only what the respective system is then capable of evaluating from the transferred data. The use could be difficult, for example, with the performance monitor, but a classic location, for example, is certainly possible.
There are inbound and outbound interfaces to manufacturers in the commercial vehicle sector, Boch confirms: We offer the integration of truck systems from the manufacturers. So, truck and trailer
combinations can also be represented together. “Likewise, we can also integrate telematics data from trailer manufacturers and also provide data to these systems.”
Retrofit System iC Plus Retro-Fit
Not only for newly equipped trailers, but BPW also offers an iC Plus solution called iC Plus Retro-Fit for existing commercial vehicles so that fleet managers can benefit from all the advantages for their existing vehicles and test the solution in the fleet. The retrofit solution represents a cost-efficient way to integrate into the fleet: “The vehicles and their performance are monitored and optimized because you recognize early when maintenance is due,” said Freudenberg.
BPW provides an amortization calculator on its website that can calculate individual savings potential.
Artificial Intelligence (AI) Integrated
The software uses certain functionalities of artificial intelligence. For example, in the Brake Performance Monitor: current braking operations are monitored and trends and quality statements are made through corresponding evaluations, as Boch explains. When working with the Cargofleet Assistant, similar systems known from Copilot and ChatGPT are used. However, only the fleet's data is used, and this is not passed on elsewhere. All data remains in the Cargofleet system, where it is evaluated accordingly with AI (Artificial Intelligence). An extension of these AI functions is currently being planned.
A presentation with illustrative further information on the solution is available, as well as all other records of the Conference Days, on the website after registration for sessions.
Commercial vehicle axle and chassis manufacturer BPW (Bergische Patentachsenfabrik Wiehl), today officially called Bergische Achsen KG, is celebrating its 125th company anniversary this year. The commercial vehicle portfolio includes axles, components such as brakes, telematics applications, and other accessories such as the Airsave tire pressure monitoring system. The BPW Group, headquartered in Wiehl, North Rhine-Westphalia, now employs approximately 6,800 employees. There is a global service network with 3,200 service partners; collaborations have been formed with, for example, ADAC TruckService. The BPW Group also includes the Munich-based system partner and software specialist Idem Telematics, which specializes in networking solutions and management systems for the
