Trucks
Trucks
By taking a proven concept from the aerospace industry and applying it to heavy-duty trucks, Volvo Trucks has further improved the aerodynamics of its vehicles – and by extension increased their fuel and energy efficiency.
Overcoming air resistance and drag has a hugely significant impact on a truck’s fuel consumption – especially in long-haul. That’s why improving aerodynamic design has long been a priority for Volvo Trucks’ engineers. In 2024, the launch of the Volvo FH Aero saw a number of aerodynamic improvements, including an extended front and replacement of the side mirrors with the Camera Monitor System. These changes have in turn created opportunities for further refinements, including these latest upgrades.
The most significant addition to the truck is the cab airflow stabilizers, located on the cab’s upper corners beside the windshield. Using a carefully designed pattern consisting of small oblique vanes, the stabilizers control the airflow to help it remain attached to the vehicle as it moves around the cab’s corners.
“The cab’s upper corners in the mirror region are where we can see a large separation of the air flow in our simulations. However, until recently we have not been able to access this particular area because of the presence of the side mirrors,” explains Anders Tenstam, Senior Technology Expert Aerodynamics, Volvo Trucks. “Once they’re removed, we have more opportunities to work on this area, which is very sensitive in terms of air flow. The air velocity in this region is very high, and a small change can have a butterfly effect. With these small vanes, we can control the air flow on a micro scale and create a macro scale effect on the truck’s overall aerodynamics.”
The technique – commonly known as vortex generators – is well established in the aerospace industry, and utilized on airplanes, Formula One race cars and wind turbines. With the cab airflow stabilizers, the concept is now being applied to heavy-duty trucks too.
The new cab airflow stabilizers help the airflow remain attached to the vehicle as it travels around the cab’s corners(left).The extended air deflectors reduce the gap between the cab and the trailer, which is particularly beneficial when driving with high side winds(right).
The cab airflow stabilizers improving aerodynamics at the front of the vehicle means better conditions are created for two additional upgrades: extended air deflectors and adjusted chassis fairings. The extended air deflectors reduce the gap between the cab and the trailer, which is particularly beneficial when driving with high side winds. The adjusted chassis fairings create better alignment with the rear fender.
While each of these upgrades would still be possible without the cab airflow stabilizers, neither would generate the same aerodynamic benefit. In short, all three work better in combination.
“Our strategy is to optimize the front of the vehicle, in order to maximize the effects further downstream,” explains Mattias Hejdesten, Senior Engineering Expert Aerodynamics, Volvo Trucks. “By implementing the cab airflow stabilizers, the effects of the extended air deflectors and adjusted chassis fairings are accelerated."
Anders Tenstam (left), Senior Technology Expert Aerodynamics, and Mattias Hejdesten, Senior Engineering Expert Aerodynamics, Volvo Trucks.
At the core of Volvo Trucks’ approach to aerodynamic development is the streamline principle, where its engineers take a holistic approach to the whole vehicle. Instead of looking at each aerodynamic upgrade in isolation, the different sections of the truck are seen as interconnected parts.
“It is a case of 1 + 1 = 3,” says Anders. “We look to create a package of improvements that complement each other, so the overall impact is greater than the sum of all parts.”
The strategy has resulted in an evolution of improved aerodynamics in recent years, where each upgrade enhances and accelerates the effects of earlier upgrades, while also creating the preconditions for further upgrades. For example, many of the aerodynamic improvements introduced in 2022 (including new seals, door extensions, fender flares and mirror arm covers) were optimized and accelerated by the improvements introduced in 2024 (extended cab front, Camera Monitor System).
It is a case of 1 + 1 = 3, says Anders. We look to create a package of improvements that complement each other, so the overall impact is greater than the sum of all parts.
“The same principle applies now,” says Mattias. “When we implement these new upgrades, we’ll see further benefits from those earlier changes. And we will also enable more aerodynamic concepts to be introduced in the near future.”
The cumulative effect of these consistent aerodynamic upgrades is lower fuel consumption and a smaller CO2 footprint. Or in the case of battery-electric trucks, improved energy efficiency and longer range. This is why aerodynamic development plays such a central role in Volvo Trucks’ ongoing efforts to improve the fuel and energy efficiency of its vehicles.
If you’d like to learn more about the importance of aerodynamics and its impact on fuel and energy efficiency, you might be interested in reading:
● Why truck design is important for fuel efficiency
● Behind the development of the Volvo FH Aero
● How the Camera Monitor System contributes to improved aerodynamics
