In recent years, the freight industry has been under increasing pressure to reduce its carbon footprint, as transportation continues to dominate greenhouse gas emissions in the United States. By 2025, heavy-duty trucks had surpassed passenger vehicles as the primary contributors to pollution, marking a pivotal shift that has placed significant focus on the need for sustainable solutions in the logistics sector. Traditional approaches to electrification, such as fully electric semis, have faced substantial barriers, including high costs, the weight of batteries, and limited range—factors that have made them inaccessible to many small fleet operators.
It is within this context that California-based startup Revoy has introduced a groundbreaking alternative: a hybrid system that enhances the efficiency of existing diesel trucks. Instead of replacing the diesel powertrain with full electrification, Revoy’s solution involves adding an electric dolly between the truck and trailer. This system enables diesel rigs to operate with improved fuel efficiency and reduced greenhouse gas emissions without requiring costly overhauls or replacements.
The dolly is equipped with a 575-kilowatt-hour battery, providing sufficient power to significantly reduce the workload on the diesel engine. This electric assistance is delivered through a combination of powered axle technology and smart integration with the truck’s existing infrastructure. The system connects to the truck’s fifth-wheel hitch via a smart kingpin, and it seamlessly plugs into existing air and electrical lines, requiring no major modifications to existing equipment. This streamlined approach allows for rapid installation, often within minutes, without the need for specialized tools.
Beyond fuel efficiency, Revoy’s system offers a range of safety and operational enhancements. Embedded sensors and cameras monitor blind spots, while real-time data is sent to the driver’s smartphone app, improving situational awareness and reducing accident risks. The dolly also enhances lane stability, assists in steering during crosswinds, and implements regenerative braking to recharge the battery. These features collectively contribute to a safer and more reliable driving experience, with no additional dashboard or user interface required for the driver.
Charging remains a significant challenge for full electric freight, with even the fastest chargers taking over 30 minutes to fully recharge a battery. Revoy circumvents this issue by utilizing a swap station model, where depleted dolly units can be quickly exchanged for fully charged ones in about five minutes. This not only accelerates the charging process but also integrates seamlessly with the existing infrastructure, offering a practical solution to the current limitations of electric freight.
The business model is designed to minimize financial barriers for operators. Instead of purchasing the dolly, truckers lease the technology on a per-mile basis, eliminating upfront capital investment and maintenance responsibilities. Revoy estimates that the system can save operators over $5,000 annually through reduced fuel consumption, with some fleets reporting up to five times greater fuel efficiency. This financial incentive, combined with the scalability of the system, positions Revoy as a viable solution for a wide range of operators, from small truckers to larger fleets.
Potential global applications are also being explored, with countries such as Australia and Canada showing interest in adapting the technology to their own logistics needs. Australia’s vast, sun-drenched highways could benefit from solar-powered swap stations, while Canada’s twin-trailer B-Doubles would require a modified version of the system. Regardless of the region, the core principle of electrifying existing infrastructure without overhauling entire fleets remains a compelling proposition for reducing emissions and improving operational efficiency in the freight sector.
Revoy’s innovation represents a significant step toward more sustainable freight transportation without requiring a total overhaul of the existing industry. By leveraging current infrastructure and focusing on incremental improvements, this system offers a practical, cost-effective, and environmentally friendly solution that is poised to reshape the future of diesel trucking.