Researchers have designed an electric truck convoy system that cuts freight operating costs by 56% through a combination of lightweight construction, aerodynamic optimization, and autonomous platooning technology.

The Robostreet Flow platform features a battery-electric 6x4 tractor with a drag coefficient of 0.35, approximately 40% lower than conventional Class 8 tractors. A carbon-composite monocoque and structurally integrated batteries reduce vehicle weight by 50%.

The system operates as a four-truck convoy with one safety driver in the lead vehicle and three followers running in SAE Level 4 automated mode. Computational fluid dynamics simulations show that close following at an 8-meter gap reduces follower drag coefficients by 42-48%.

Energy and Cost Benefits

The convoy configuration delivers fleet-average consumption of 1.27 kWh per mile, compared with 1.60 kWh per mile for isolated vehicles — a 20.5% energy saving. Each truck carries a 513 kWh tractor battery plus a 340 kWh powered trailer battery for 500-mile range.

Electricity costs run approximately 17% of equivalent diesel fuel expenses. Combined with the driver efficiency gains from operating four trucks with one person, total operating costs drop from 9.4 to 4.1 cents per ton-mile.

The research team, led by Wei Wang and colleagues, submitted their findings to IEEE Transactions on Intelligent Transportation Systems. The paper includes sensitivity analysis and regulatory considerations for hub-to-hub freight operations.

Several companies are pursuing similar autonomous freight approaches. Einride operates electric autonomous trucks in Sweden, while Aurora focuses on self-driving technology for long-haul trucking. Waabi develops generative AI specifically for autonomous vehicles.

The Flow system targets high-volume point-to-point corridors where consistent routes can maximize the benefits of convoy operations and shared driver costs.