When discussing electric heavy-duty trucks, the massive battery pack located behind the cab is always the first thing to catch the eye. Known as a ‘roof-mounted’ or ‘backpack-style’ battery pack, this design has become the most widely adopted power solution in the electric heavy-duty truck sector thanks to its mature and reliable technical characteristics.

From a technical architecture perspective, it follows the classic three-tier design logic of ‘cell-pack-battery assembly’: first, thousands of lithium-ion cells are assembled into standardised modules, each acting as an independent energy unit with built-in precision temperature control and management systems;these modules are then connected in series via a high-voltage electrical system, encapsulated as a whole within a robust metal enclosure, and finally mounted above the chassis to form the heavy-duty truck’s “energy backpack”.

However, whilst the industry is developing rapidly, a number of deep-seated challenges are gradually coming to light.

Industry Pain Points: Lack of Standardisation and Lifespan Challenges

Currently, the most prominent issue in the electric heavy-duty truck battery sector is the slow pace of standardisation. Major vehicle manufacturers and battery suppliers operate independently regarding interface protocols, communication standards and mechanical mounting methods, leading to severe market fragmentation. This ‘feudal’ landscape not only drives up procurement and maintenance costs for operators but also hinders the large-scale development of charging and battery-swapping infrastructure, becoming a key bottleneck constraining the industry’s overall development.

In addition to inconsistent standards, service life also faces severe challenges. Practical testing indicates that, under identical operating conditions, overhead-mounted battery packs are subject to continuous vehicle vibrations, which directly impacts the full lifecycle operating costs of logistics companies. Furthermore, due to uneven heat dissipation, there is often a temperature difference of 5–8°C between the edges of the battery box and the central modules; prolonged operation leads to inconsistent battery degradation, further shortening the overall service life of the battery pack.

The Future is Here: Standardisation is the Clear Trend

The application scenarios for electric heavy-duty trucks are becoming increasingly diverse, and the demands on battery technology vary significantly across different scenarios. In fixed-route scenarios such as ports and mining areas, the battery-swapping model is rapidly gaining traction due to its efficient recharging advantages. However, the incompatibility of battery packs from different brands with swapping equipment leads to redundant infrastructure construction, low utilisation rates, and difficulties in maximising investment returns.

From the demand side, the explosive expansion of the lithium-ion battery market has made standardisation an inevitable direction. According to forecasts, China’s lithium-ion battery demand is set to surge from 93 GWh in 2019 to 1,780 GWh by 2030, whilst the global market is expected to expand at an average annual growth rate exceeding 13%. Emerging markets such as China, Europe, the US and Southeast Asia are collectively driving this growth, with power batteries accounting for over 80% of total demand.In the domestic context, passenger vehicles remain the core driver of power battery demand (accounting for over 75% of demand in the long term), whilst demand for lithium-ion batteries in commercial vehicles, such as medium and heavy-duty trucks, is also rising steadily alongside market penetration. This multi-scenario, large-scale surge in demand is compelling the standardisation of power battery packs, including those for electric heavy-duty trucks, to facilitate coordinated supply, cost control and efficiency improvements across different application scenarios.

Data sources: IHS; Gaogong Lithium Battery; China Society of Automotive Engineers’ series of exchange interviews with leading power battery enterprises; literature review

Technological Innovation: Nengyixing’s Technological Breakthrough in Battery Pack Systems

Faced with common industry challenges, some enterprises have pioneered new pathways through technological innovation. Take Nengyixing’s “Nengxin Series” as an example: this standardised battery integration system, specifically designed for new energy heavy-duty trucks, has focused on the two key concepts of “compatibility” and “flexibility” from the very outset of its design.

Its core innovation lies in the “same frame, different cells” technical concept: through standardised battery frame and base tray interface designs, it can be widely adapted to base trays, lifting equipment and battery-swapping devices from mainstream brands, achieving cross-platform compatibility. More importantly, within the same standardised framework, battery packs from different manufacturers can be integrated, supporting flexible combinations of energy capacity and power output, thereby truly realising “one frame for multiple uses, configured to demand”.

Regarding mechanical structures critical to reliability, the Nengxin series employs a proprietary multi-link locking mechanism with self-locking functionality, ensuring a secure and reliable battery connection even on the bumpy roads of mining areas or during long-distance high-speed driving.

Furthermore, through an integrated design approach, the system tightly integrates the high-voltage box, BMS management system, B-BOX and charging interface. This not only results in a more compact layout and lower costs, but also reduces the overall height of the battery pack by 5%, making it compatible with a wider range of vehicle models. The entire series utilises S700L high-strength steel, achieving a 15% weight reduction whilst ensuring structural safety, which directly enhances vehicle energy efficiency and handling agility.

Combining these technological innovations, the design service life of the Nengyi Xing battery pack can be extended to over eight years. In high-intensity operational scenarios such as those encountered by heavy-duty trucks, this significantly enhances the long-term return on investment for users. This also underscores a fundamental principle: in the race towards scale, only technological innovation grounded in standardisation and guided by real-world operational needs can truly win the market and secure the future.

The path to the widespread adoption of electric heavy-duty trucks is also the evolution of battery packs towards standardisation, compatibility and lightweight design. From early-stage technological exploration to today’s scenario-specific adaptation, the industry is gradually moving beyond the rudimentary phase of ‘everyone for themselves’ and entering a new era of open collaboration and interconnectedness.In the future, battery packs will no longer be merely ‘power components’ for heavy-duty trucks, but rather standardised energy units within the entire green transport network – interchangeable, upgradeable and transferable – truly becoming the cornerstone energy source driving the logistics industry’s low-carbon transition.