The latest interviewee in our PhD series of talks with RWTH students is Theo Koch, who works at the Institute for Automotive Engineering and does research concerning the optimisation potential of commercial HGV fleets and the related challenges of integrating zHGVs into fleet management solutions.
Please describe your research to a wider stakeholder audience and highlight innovative aspects.
I’m researching the optimisation potentials of commercial fleets, which include vehicles with combustion engines, as well as hydrogen-fuel cell and electric vehicles. The challenges of the fleet operator is to maximise route efficiency and vehicle utilisation, which are planning tasks that are supported by models and software solutions. Adding zHGVs to such planning significantly increases the complexity, especially due to the limited availability of (ultra-)fast charging or refuelling stations for zHGVs. Thus, my research focuses on the development of models that optimise fleet operation and include zHGVs efficiently.
What is the connection with the ESCALATE project? How do you benefit from the project, and what synergies exist?
The ESCALATE pilots provide us with the possibility to gain knowledge and insights regarding the charging and refuelling process, which helps us to enhance our existing models related to recharging and refuelling times, as part of the fleet operation tool.
Developing and building the pilot vehicles also gives us the possibility to conduct tests and validate the simulation models we build during the development. With the validated simulation models, we can predict the energy demands of all the different fleet vehicles under different environmental conditions. This helps our model to find highly efficient fleet operations while also reducing the risk of vehicles running low on energy with no close charging point or hydrogen refuelling station.
With your expertise and the perspective of your research, where do you currently see the biggest challenge in a large-scale deployment of zero-emission trucks?
Most major truck manufacturers are rolling out zHGVs for long-haul operations. These vehicles have a greater purchasing cost, but the operational costs tend to be a lot lower. Depending on the use case and the expected total period of ownership, battery electric vehicles can have a TCO, which is already close to conventional ICE trucks.
In my assessment, fleet operators are still very concerned about the range and costs of the vehicles. The question is whether the vehicles will work for their operation and with the corresponding charging points and hydrogen filling stations in the vicinity, and whether they can achieve competitive TCO values compared to conventional vehicles. As of yet, there are no models for automated fleet operation optimisation that seamlessly integrate these new drive technologies. With ESCALATE and my research in this field, we are working on changing this soon.
What do you think could be the impact (or lack thereof) of projects like ESCALATE on the promotion of zHGV technology/solutions?
Projects like ESCALATE can have a significant and multi‐dimensional impact on promoting zHGV technology. For one, they act as high‐visibility demonstrators that validate innovative powertrain concepts and modular components under real-world conditions. This not only helps de‐risk the technology for investors and manufacturers but also creates a reference benchmark that can accelerate industrial uptake.
Moreover, by integrating fast fuelling and grid-friendly charging solutions with digital tools (like digital twins and AI-based fleet management), ESCALATE fosters a holistic ecosystem for zero-emission heavy-duty vehicles. This ecosystem approach can influence regulatory frameworks and standardisation efforts, which are critical for scaling zHGV solutions across Europe.
However, the overall impact ultimately depends on how well the project’s innovations translate into cost-effective, reliable, and scalable solutions. If successful, projects like ESCALATE can drive market transformation, spur additional R&D funding, and shape policy incentives—all of which are essential to overcoming current barriers such as high upfront costs and infrastructure readiness.
In summary, while challenges remain, the collaborative and demonstrative nature of ESCALATE is a key catalyst in moving the heavy-duty transport sector toward a net-zero future.
What is the biggest challenge that freight operators need to overcome to rapidly decarbonise their fleet, and how can your research help?
Freight operators face a dual challenge in decarbonising their fleets: they must integrate new, zero‐emission technologies into operations while ensuring that these vehicles remain reliable and cost‐effective. One of the biggest hurdles is the current mismatch between operational demands and the availability of charging and hydrogen refuelling infrastructure. Unlike conventional diesel trucks, battery and fuel cell electric vehicles require longer refuelling or recharging times, and their routes may need to incorporate detours to reach the nearest station – factors that can disrupt tight delivery schedules and affect the overall total cost of ownership.
My research addresses these challenges by developing an advanced, automated fleet operation optimisation model tailored for heterogeneous fleets. This model accurately predicts key parameters such as energy demands, charging durations and detour distances in order to route the vehicles with charging and hydrogen refuelling strategies. By doing so, it provides freight operators with realistic, data‐driven routing strategies that can minimise energy downtime and prevent range anxiety.
In essence, by optimising route planning to account for the unique demands of electric and hydrogen-powered trucks, my research helps to reduce one of the major operational barriers. This, in turn, paves the way for rapid fleet decarbonisation and supports the transition toward a more sustainable and competitive freight sector.