Saving emissions in freight transport through lightweight construction? H-BRS analyses environmental impact

H-BRS team carries out life cycle analysis

In order to test the effects of the lighter weight, automotive supplier ZF Friedrichshafen has developed a prototype of a stabiliser support - a component that counteracts the rolling of trucks when assembled with a stabiliser when cornering. The H-BRS research team led by Professor Stefanie Meilinger accompanied the development process with a so-called life cycle analysis. The researchers analyse the environmental impact of a product - throughout its entire life cycle, from production to use and disposal. 

Unlike usual, the experts were involved in NeLiPro right from the start: "Normally, sustainability factors are only analysed after the product has already been developed. However, the project clearly showed that it is worth considering the life cycle assessment right from the start," says Stefanie Meilinger. For example, an initial draft still envisaged replacing steel parts of the reference product with aluminium. However, this resulted in an unexpectedly high level of emissions during production, which is why this was ultimately abandoned. "If you are interested in achieving the most effective results possible, you should include sustainability aspects as early as the product development stage," says Meilinger.

The type of drive plays a decisive role

In terms of weight, ZF Friedrichshafen was able to save around 14 per cent, approximately 300 grams, on the stabiliser support compared to the reference product. However, the researchers are sceptical as to whether this will lead to the entire vehicle being manufactured from lightweight components in the future: "Making trucks lighter has a positive effect on emissions. However, this effect varies depending on the type of drive used. The method is most effective when diesel engines continue to be used," says Eva Jurgeleit. When using alternative drive types, such as electric or hydrogen engines, the savings are significantly lower.

A holistic analysis also includes pointing out the poor properties of the lightweight rod after the period of use. For example, the material can no longer be dismantled into its individual parts after use in the lorry and therefore cannot be reused. In contrast, this is possible with the reference product, which is largely made of metal.