Daimler Truck builds ‘front box’ for eActros 600 electric truck in series production

Daimler Truck describes the so-called front box as a complex technology module with several control units, high-voltage components and an electric air compressor. It contributes to the operation of the heavy-duty eActros 600 – but not to the drive itself. A type of front box was already used in the eActros 300/400 with a market launch in 2021. The bigger brother is now receiving an enhanced version, which is now rolling off the production line at the engine plant in Mannheim-Waldhof. The front box will then be installed in Wörth, where the actual series production of the eActros 600 is based.

“Accommodating this high number of components in a very confined space was a particular challenge during the development process. In the end, this was achieved by means of a so-called ‘layered structure,’ in which the individual components are built up from bottom to top,” says the truck manufacturer, which has formed a production team of 25 employees for the new area, which could “expand to up to 170 employees in the future.”

Daimler Truck spent around a year renovating a 5,500 square metre area at its traditional plant in Mannheim in order to integrate the production line and logistics zone for the new module. Care was taken to make it particularly future-proof: The line offers “a high degree of flexibility for different quantities, product variants and subsequent generations,” according to the manufacturer. Specifically, the assembly line is made up of four consecutive sections, each of which houses different assembly stations with their own material zones and pre-assembly. Each section concludes with a ‘quality gate’ for inspection, completed by the so-called end-of-line inspection.

Meanwhile, final preparations for the eActros 600 are also underway at the component plants in Gaggenau and Kassel, as these sites will also be supplying parts, including axle and transmission components. The electric long-haul truck will officially make its series debut at the end of November in Wörth, where everything comes together. The first customer vehicles will then be manufactured and registered before the end of the year. The vehicle is known to have celebrated its world premiere in October 2023.

Meanwhile, those responsible in Mannheim are satisfied that a central part of the alternatively powered eActros 600 has been localised in Mannheim. Andreas Moch, site manager for the Mannheim plant, says: “The front box is an assembly-intensive unit for battery-powered vehicles. After a successful prototype phase, we are now pleased to be able to move into series production.” Mannheim is the centre of excellence for battery technology and high-voltage systems at Daimler Truck. “With the start of production of the front box, we are already reaching the second milestone this year, after we opened our Battery Technology Center in the summer,” says Moch.

Bruno Buschbacher, Chairman of the Works Council at the Mercedes-Benz plant in Mannheim, also believes that the site is well positioned for the transformation: “I am very pleased that we have successfully launched the first product, the front box, under the agreement concluded in 2021, and that part of the powertrain for the alternative drives is now located in Mannheim. This is an important step in the transformation of our long-standing engine plant. The vertical range of manufacture of the future must continue to enable us to produce essential components ourselves.”

Update 11 November 2024

In preparation for the start of series production at the end of November, Daimler Truck has begun manufacturing further components for the eActros 600. As with the eActros 300/400, key parts of the e-axle come from the Gaggenau plant, which specialises in heavy commercial vehicle transmissions. These include specially developed transmission components such as shafts, gear wheels, synchroniser parts, as well as housing parts. Gaggenau supplies these components to Kassel, where the complete assembly of the axle and transmission components takes place, resulting in the newly developed, electrically driven rear axle. The eActros 600 has a specially developed four-speed gearbox.

In addition, the bodyshell components for the cab of the eActros 600 are also manufactured in Gaggenau. The scope includes structural body-in-white parts such as the rear wall, roof frame, bulkhead and cross members, as well as various reinforcements. These are identical parts that are already used in the conventionally powered truck.

daimlertruck.com, daimlertruck.com (update)