JM 31.12.2024

Theme Ic Retrofitting existing vehicles


Content of this page

1. Description of the current situation, today
2. The requirements for existing vehicles

3. Solutions for retrofitting
4. Advantages and disadvantages of retrofitting
5. Summary


1. Description of the current situation, today

We are only at the beginning of the industrial production of electric vehicles. At the same time, the production of new battery types is being intensively expanded, with the development of more efficient and more powerful batteries being driven forward at full speed.
Many manufacturers have already decided to produce only electric vehicles in the future - a trend that is also spreading to lorries and buses. There is to be a ban on new combustion vehicles from 2035, but there is still a long way to go.
Meanwhile, the climate problem continues unabated (see homepage, point 8).
Existing vehicles in Europe and worldwide:

  • Europe:
  • Approx. 300 million cars and 6.4 million lorries (as of 2023)
  • Annual new registrations: 1.8 million (2023)
  • Worldwide:
  • 1.5 billion cars and light commercial vehicles (as of 2023)

The average lifespan of cars in Germany is 9.6 years, for lorries approx. 8.5 years. However, many vehicles are sold on after being used in Germany and are often driven in other countries for many years. The actual service life is therefore difficult to determine.

The problem:
Even with the ban on new combustion engines from 2035, millions of existing vehicles will still be on our roads well into the middle of the century.
Why retrofitting makes sense:
A look at other industries shows that longevity through modernisation is often standard:

  • Trains: an ICE train is planned for around 25 years, overhauled once and manages 12 million kilometres.
  • Aeroplanes: Passenger planes are taken out of service after 25-30 years or converted into cargo planes, which is quicker and cheaper than buying a new one.
  • War vehicles: Are regularly modernised, as new developments take a very long time.

So why not cars too?
There are numerous examples of long-lasting vehicles, such as classic cars or a Scania lorry with 3 million kilometres in 25 years. However, many classic cars struggle with the problem of a lack of spare parts, as manufacturers only provide these for a limited time (EU requirement: 7 years, some German manufacturers offer up to 10 years).
There is already a niche market for retrofitting existing vehicles. However, it is always an individual service and therefore very expensive. With mass production, many things can be simplified.


2. The requirements for existing vehicles (cars, trucks, buses)

How do we harmonise these thoughts with the problems of our climate, because we want to switch to electric drives because of the climate problems?

2.1 Specifications for end-of-life vehicles

  • The service life for combustion engines and trailers is extended to 50 years,
  • All vehicles built after 2000 are included,
  • All spare parts must be kept in stock by the manufacturer,
  • For all vehicles built after 2000, manufacturers must, provide a conversion kit for electric drive with the latest generation motor and battery; the costs must be lower than a replacement motor, (some are already on the market),
  • Requirements at least: 400 km WLTP, 250 km charging in 10 min. Trailer operation must be taken into account,
  • Trailer manufacturers offer e-drives for trailers including batteries, which are controlled in coordination with the towing vehicle,
  • It should always be possible to bring the vehicles up to the latest state of the art with updates and additions.  It applies to all parts of the vehicle built from 2000 onwards. The customer decides whether to accept the update,
  • The replacement of batteries is massively simplified, so that the latest generation can always be installed easily,
  • Replacement of interior parts up to complete replacement is offered,
  • Body parts made from sheet metal can be easily replaced with new parts made from new materials, e.g. with 3D printers,
  • Trucks and trailers or semi-trailers are equipped with automatic coupling systems to enable autonomous industrial estates (theme IV).

JM 01.01.2025

2.2 Necessary regulations

  • Every vehicle manufacturer that registers new vehicles from 2026 must fulfil all points under 1,
  • From 2026, new vehicles will only be registered if an ‘end-of-life vehicle’ is deregistered and 100% of it is verifiably recycled with climate-neutral transport,
  • The number of registered vehicles will remain the same as on 1 January 2025.

JM 01.01.2025

2.3 Validity

  • These requirements apply to all combustion vehicles, from small cars to lorries and buses,
  • New vehicles must prove that all components can be easily replaced for registration,
  •  Statutory regulations for registration and MOT are being adapted.

2.4 Aims

  • Reduce the production of new vehicles, which have a significant impact on the environment due to the enormous consumption of materials and energy,
  • The number of new vehicles produced is to be reduced by 40% by 2030 compared to 2023 and by a further 10% to 90% per year compared to 2023,
  • The conversion of end-of-life vehicles will continue to save resources, primarily by extending the service life of vehicles,
  • Establishing a recycling system for the replaced parts, especially the engines,
  • These requirements initially apply in Germany and are to be extended to the EU and worldwide,
  • The aim is to contribute to climate improvement in the mobility sector.

JM 01.01.2025

2.5 Open goals

The other currently unresolved problems such as accidents with fatalities and injuries, tyre wear and the need for sealing are described in other topics on this page. (Theme Ia and Ib).

 

A very important and decisive goal must be solved, the social solution to this transition. Without social support, the goal of climate protection cannot be achieved. This applies to all countries.

 

Here are some ideas:
1. charging 8-year-old retrofitted vehicles is always free of charge,
2. the kilometres used are billed with the borderless European ticket, see topic II, where all social possibilities are already presented,
3. the retrofits can be paid for as a lump sum with a type of insurance,

03.01.2024


3.  Solutions for retrofitting

A video by Prof Maximilian Fichtner. A lot of information about new energies is presented here. This has also led to this idea of retrofitting.

Only in German

JM 02.01.2025



Two pictures from Prof Fichtner's lecture on the capabilities of new batteries.

JM 02.01.2025



The largest electric dump truck in the world, from Switzerland, with a total weight of 123 tonnes. (in german)

JM 02.01.2025



4. Advantages and disadvantages of retrofitting

4.1 Advantages

With a view to the climate:

  1. Reduced resource consumption:
    1. The massive reduction in the production of new vehicles significantly reduces the global demand for raw materials such as metals, rare earths and plastics.
  2. Energy savings:
    1. The energy required to produce new vehicles is drastically reduced, leading to a more sustainable use of global energy resources.
  3. Land and environmental protection:
    1. Today's huge production facilities could be reduced or repurposed, avoiding land sealing from new construction.
  4. Rapid reduction of pollutants:
    1. Converting existing vehicles to electric drives enables a significant reduction in CO2 and NOx emissions in a short space of time.

For us as users or customers:

  1. Continuity:
    1. Vehicle owners can keep their current vehicles and still benefit from continuous technological updates that take into account environmental standards and the latest technology.
  2. Contribution to climate protection:
    1. Every vehicle owner can make an active and sustainable contribution to reducing emissions by retrofitting.
  3. Customised improvements:
    1. There are many opportunities to modernise existing vehicles, for example through comfort-enhancing or safety-related additions that go beyond the drive system.
  4. Customer loyalty:
    1. Vehicle owners remain loyal to a manufacturer for longer as their vehicle remains up-to-date thanks to regular upgrades. This strengthens the bond between customer and manufacturer.

For the industry:

  1. New business models:
    1. The conversion of existing vehicles represents a real revolution and marks the transition to a more climate-friendly industry.
  2. Changing energy priorities:
    1. With the increasing demand for electric drives, the generation and distribution of clean electricity is becoming even more central. The transformation of the energy supply is being driven forward.
  3. Expansion of the charging infrastructure:
    1. Roads, car parks and multi-storey car parks will be equipped with more charging stations, making the switch to electromobility easier and more convenient for everyone.
  4. Innovation boost:
    1. Manufacturers can take a leading role worldwide through standardised conversion solutions and expand their expertise in sustainable technologies.


This list is only an initial overview. A complete analysis should be prepared by experts who comprehensively assess all aspects, from the ecological to the economic.


4.2 Disadvantages

With a view to the world of work:

  1. Massive changes in the world of work:
    1. A reduction in vehicle production to around 10% of the current level would mean a significant intervention in the world of work.
  2. Loss of jobs:
    1. Similar to the textile and coal industries, many jobs will disappear, especially in vehicle production and supplier companies.
  3. Loss of sites:
    1. Production sites could be closed, which would hit structurally weak regions particularly hard.
  4. Slump in the supplier industry:
    1. In addition to the changes already foreseeable as a result of the switch to electric vehicles, the conversion of existing vehicles will result in further reductions at suppliers.
  5. Challenges for garages:
    1. Both large and small garages will have to adapt. Many could close because they cannot meet the requirements of the new technologies or because the market is shrinking.
  6. Transformation of the oil industry and petrol stations:
    1. The oil industry and petrol station operators will have to adapt significantly as demand for fossil fuels continues to fall.

Alternative solutions for the world of work:

  1. The innovations listed in Theme III Freight transport by rail in relation to new locomotives and freight wagons, as well as the new train formation systems, offer quick compensation measures,
  2. The technologies listed in Themes Ia and Ib relating to new cableways or magnetic rails also offer rapid compensation measures.

The relocation of investments and tasks, which can also be seen worldwide, will hardly result in any losses, either in terms of jobs or companies.

For the customer:

  1. Cost burden:
    1. Retrofitting and continually updating vehicles will be a financial challenge for many customers, especially those who can rarely or never afford a new car.
  2. Changes in the used car market:
    1. The used car market could change drastically. Vehicles that are regularly updated could command higher prices, which could penalise lower-income buyers.
  3. Social and financial challenges:
    1. A global transition will require new, smart and socially responsible financing solutions. Without these solutions, many people and countries would not be able to manage the transition.
  4. Uncertain market reactions:
    1. It is difficult to predict the long-term impact on the car market and price trends. This could create uncertainty for buyers and manufacturers alike.

This list provides an initial overview; the comprehensive assessment and detailing should be carried out by experts in order to precisely assess the scope of the changeover and develop suitable countermeasures.


4.3 Something human

For many people, the car is much more than just a means of transport - it is a status symbol, an expression of personality and often also a piece of freedom.
But this role of the car will change. There will continue to be large and small vehicles, but the classic new purchase could become significantly less important. Instead, the value of a car will no longer be defined solely by its age or brand, but by its ability to constantly adapt to new technical and ecological standards.


But aren't we all learning that we can no longer carry on as before?


Our use of resources, energy and mobility must change if we want to meet the challenges of the climate crisis. It is an opportunity, not just for industry and politics, but for all of us, to break new ground and question old habits.


5. Summary

We've all been on board the Titanic since around 1970. We rammed the iceberg around 20 years ago - the climate problem has long been a reality.

But instead of taking decisive action, we are arguing about who should foot the bill for the food.

Shouldn't we finally start to repair or at least contain the damage?

If we can't do that, the bills will be redundant,
because there will be no one to pay them.


When it comes to money, here is the link to the start page with corresponding documents on Global debt and future climate damage.

 

Future global climate damage approx. 38 trillion dollars per year, 1,000 billion dollars in 25 years,

Global government debt over 100 trillion dollars,

 

Global debt, private households, companies and states over 282 trillion dollars.

 


We should also ask questions here and think in a radically new way.



If you find any errors, we would be grateful for any information.