A Dashboard for Trucking Efficiency, an HVAC Game Changer, and More Power With Less

Are you curious about new technologies that maximize performance while minimizing energy use and costs? If yes, this episode is for you. Learn about: 

• A tool package that is helping trucking companies reduce fuel usage and costs by streamlining their fleet design and logistics.  
• A breakthrough in air conditioning that transforms how we condition air and when we use electricity to do it. 
• A silicon-carbide-based power module with never-before-seen efficiency, power density, and low-cost manufacturability. 

This episode was hosted by Kerrin Jeromin and Taylor Mankle, written and produced by Allison Montroy, Hannah Halusker, and Kaitlyn Stottler, and edited by Taylor Mankle, Joe DelNero, and Brittany Falch. Graphics are by Brittnee Gayet. Our title music is written and performed by Ted Vaca and episode music by Chuck Kurnik, Jim Riley, and Mark Sanseverino of Drift BC. Transforming Energy: The NREL Podcast is created by the U.S. Department of Energy’s National Renewable Energy Laboratory in Golden, Colorado. Email us at podcast@nrel.gov. Follow NREL on X, Instagram, LinkedIn, YouTube, Threads, and Facebook.

Transcript

[intro music] 

Taylor: Welcome to The NREL Podcast, brought to you by the U.S. Department of Energy’s primary national laboratory for energy systems research, development, and integration. We’re highlighting the latest news happening at the lab. I’m Taylor Mankle.  

Kerrin: And I’m Kerrin Jeromin. 

Taylor: Before we get into today’s episode, we want to remind you all that we would love for you to subscribe and give us a five-star review on your preferred podcast platform.  

Kerrin: Absolutely, we would love to hear from you and hear what you think of the show. 

Taylor: Exactly, now today we have an episode all about innovations that maximize performance while minimizing energy use and costs. 

Kerrin: That's right, today we’re talking fleet transportation, air conditioners, and next-gen power modules. From the roads we drive on, to the buildings we live in, to the power that keeps it all running. Let’s get into it! 

[music] 

Taylor: So Kerrin, when was the last time you saw a semi-truck on the interstate?  

Kerrin: Uh, yeah, like every single time, right? The better question is: When do you not see semis on the interstate? 

Taylor: Ha! Exactly, my Grandpa would love to hear you say that, he was a proud truck driver in his day. And as you guessed, it was a trick question, because they’re everywhere—and for good reason. Trucks are how we get just about everything: groceries, electronics, furnitures. If it’s in your house, chances are it rode in an 18-wheeler. 

Kerrin: Right, but that one truck you see on the road is really just the tip of the iceberg, right. Because it is a whole interconnected system that makes sure stuff gets from A to B as quickly—and as efficiently—as possible. 

Taylor: Which is no small task. Trucking is complicated. So when researchers think about lowering costs or improving efficiency, they can’t just look at one truck; they need to consider the whole fleet, and big-picture questions like: “If we tweak this part of the system, what else does it affect?” 

Kerrin: Yeah, and that’s where the Co-Optimization of Vehicles and Routes project—also known as CoVaR, for short—comes into play. Funded by the Department of Energy, it’s all about building smarter tools for drivers and fleet managers, right on their dashboards and computer screens. 

Taylor: Yes, and this is a big collaboration: NREL teamed up with PACCAR, their subsidiary Kenworth, plus Esri, Kopius, and The Ohio State University. Together, they built a technology package that helps companies cut fuel use and costs, focusing on four big areas: vehicle configuration optimization, efficient routing, driver coaching, and a fleet performance dashboard. 

Kerrin: That’s a mouthful, so let’s take it piece by piece. The first tool in the package, a vehicle configuration optimizer, came from Ohio State. It crunches real-world data, like trip length, road grades, and cargo weight, then uses machine learning to predict how much fuel different trucks would use. 

Taylor: From there, the optimizer can tell fleet managers: “This is the most efficient mix of trucks and powertrains for the routes you run.” So instead of guessing, companies can use data to inform their fleet operations. 

Kerrin: Another tool in the package tackles routing. NREL researchers pulled in tons of real-world data from the laboratory’s FleetREDI analysis platform and the Fleet DNA database, as well as NREL’s FASTSim and Route Energy Prediction Model tool, also known as RouteE. These databases represent the gold standard for research-grade commercial vehicle data, where NREL compiles info from fleets across the country on things like: vehicle weight, drivetrain, fuel type used by the vehicle, and cities or states where fleet depots are located. Paired with project partner Esri’s mapping software, this data enables fleet managers and drivers to see the most fuel-efficient route for a specific truck and engine type—not just the fastest or shortest path. 

Taylor: And here’s the cool part: fleet managers, truck operators, and drivers can interact with each of these tools at their fingertips. Fleet managers get a web interface, and drivers get a tablet mounted right on their dashboards. The software on the truck’s display not only provides route information, but also: coaching. 

Kerrin: Right. NREL researchers looked at how driving habits—like idling, speeding, or accelerating—impact fuel use. And they built recommendations directly into the software. So, a driver might get a gentle nudge on their tablet to you know, ease off the gas or reduce idling, tailored to their truck and whether they’re hauling a light or heavy load. I mean, wouldn’t that be so cool, if we could get those kinds of nudges when we’re driving? I, for one, would benefit from that.  

Taylor: Absolutely, that’s so right! So in a real-world setting, fleet managers would visualize the vehicles in their fleet using a digital dashboard to identify the most energy-efficient combination of vehicles to send out on a given day. That interface? Built by project partner Kopius. 

Kerrin: Though the CoVAR package must be validated and commercially launched before it becomes available to fleet managers, the NREL team sees this as a near-term possibility, thanks in no small part to the many partners and collaborators who pitched in. 

Taylor: Ah yes, nothing better than a good team science project.  

Kerrin: Ain’t it the truth? I kind of think of our podcast like that, Taylor. 

[music] 

Kerrin: Alright, from transporting our goods to transporting something else just as important: cool air, into our buildings! We’ve got a development that could be a gamechanger for the HVAC industry. In fact, it just won a prestigious R&D 100 Award.  

Taylor: Better air conditioning is always welcome, and after this past summer, I think we all agree. A new technology by NREL and Blue Frontier Inc.—the Energy Storing and Efficient Air Conditioner, also known as ESEAC—offers a solution to lower a building’s electricity bills and take pressure off the grid. 

Kerrin: The ESEAC technology is designed for commercial buildings, and it combines energy storage, cooling, and humidity control all in one—cutting peak air conditioning power demand by, get this, more than 90% and lowering electricity bills by almost half. NREL’s Eric Kozubal, a senior engineer and co-inventor of the technology, calls it “a huge step forward for air conditioning.” 

Taylor: What’s so gamechanging about it is when and how it uses energy. ESEAC shifts the most energy-intensive part of cooling to off-peak hours, when electricity is cheaper and the grid is less stressed. 

Kerrin: Okay, and how does it do that exactly, you may ask? Through something called a liquid desiccant to pull moisture out of the air, then ultra-efficient evaporative cooling to bring the temperature down. This is different from conventional AC units that cool and dehumidify the air at the same time, often by overcooling and then reheating the air—which as you may guess…is about as inefficient as it sounds.  

Taylor: Yes, it takes a lot less energy to separate cooling from dehumidifying the air. And with built-in energy storage, the system works without cranking compressors during expensive peak hours of the day. 

Kerrin: Yes, storing energy in saltwater and pure water is key here; it costs about ten times less than battery-based systems. That means ESEAC provides a scalable, lower-cost way to manage cooling loads. 

Taylor: Jason Woods, an NREL senior engineer and co-inventor, says the ESEAC cycle enables on-demand cooling and dehumidification, meaning “the air conditioner can keep you comfortable all day but consumes the majority of its electricity when rates are low or renewable energy is available.” 

Kerrin: This is important because air conditioning is a top driver of peak demand, electrical consumption, and is a major reason for costly grid expansion. A year-long simulation in Miami, Florida, showed that a 20-ton ESEAC system reduced cooling-related electricity use by 38%, peak demand by 93%, and annual electricity costs by 45%. Okay Taylor, any ideas of how much money that adds up to? 

Taylor: Money talks, but I have no idea, lets hear it. 

Kerrin: Yeah, I know, I had to, of course, read the stat myself. But it’s about $165,000 in savings per unit over 15 years. That’s a lot of money. 

Taylor: That's incredible. And with support from investors like Breakthrough Energy Ventures, plus utilities and partners, Blue Frontier is installing units at sites across the country. 

Kerrin: Right, places like Fort Benning in Georgia, Westover Air Reserve Base in Massachusetts, an IMAX theater in Florida, and even hospitals and universities. 

Taylor: Those real-world installations are already lining up with the simulation results, showing big energy savings and financial wins for building owners. 

Kerrin: Now that’s pretty cool! Get it, Taylor? 

Taylor: Ice cold Kerrin, ice cold. 

[wind blowing sound?] 

[music] 

Kerrin: Okay, our final story today considers: how do we get more use out of the energy we already produce, and at a lower cost? 

Taylor: If we can figure that out, we could maybe meet the rising energy demands needed to power things like data centers, artificial intelligence, and increased manufacturing.  

Kerrin: To get there, NREL researchers have created a silicon-carbide-based power module, which is a small device that houses power electronics. In other words, it helps make electronic systems “go.” The power module NREL created features record-setting efficiency, power density, and low-cost manufacturability. 

Taylor: It’s called ULIS, or the Ultra-Low Inductance Smart power module. Based on silicon carbide semiconductors, ULIS delivers five times the energy density of other state-of-the-art modules, all in a smaller, lighter package. 

Kerrin: One of the breakthroughs about ULIS is how it enables ultrafast, ultraefficient switching of electrical current into usable forms. This ability to ‘squeeze’ more usable power from electricity makes it ideal for high-intensity applications, like aviation and military operations. 

Taylor: It’s also powerful enough to monitor its own state of health, predicting the health of its components before they fail. For planes flying 30,000 feet above sea level or military vehicles traveling through combat zones, that can mean the difference between life and death for so many. 

Kerrin: Yeah–that’s so impactful, right. And interestingly enough, the shape and architecture of ULIS was key to its development. Since it switches on and off so quickly, researchers needed a layout that kept electricity moving freely, without obstructions. 

Taylor: Early designs looked like a flower with semiconductors at each petal or a hollow cylinder with wiring on the inside; though, each iteration proved too expensive or too complicated—until researchers stopped thinking in three dimensions. 

Kerrin: Sarwar Islam, a power electronics researcher on the ULIS team, came up with the module’s almost flat, 2D structure, which made it possible to create a smaller, lighter package. That small size translates into big cost savings.  

Taylor: Yes, and the materials ULIS is made from also help bring down the cost while boosting performance. Instead of bulky, rigid copper-on-ceramic designs, ULIS bonds copper to a flexible polymer called Temprion. It’s thinner, lighter, easier to configure, and can be made quickly with common tools—for hundreds, not thousands, of dollars. 

Kerrin: And ULIS can also function wirelessly, as an isolated unit that can be controlled and monitored without external cables. The patent for this low-latency wireless communication protocol, also spearheaded by Sarwar Islam, is pending. 

Taylor: Finally, while the semiconductors that power ULIS are state of the art, the research team has intentionally “future proofed” the design. It can work with next-gen semiconductors like silicon carbide, gallium nitride, and even gallium oxide as technology advances.  

Kerrin: Taken altogether, ULIS is a 1200-volt, 400-amp module ready for data centers, power grids, micro-reactors, and heavy-duty vehicles, including next-gen aircraft. Its biggest impact could be modernizing the grid, enabling advanced aircraft, or even powering cities and fusion reactors. 

Taylor: ULIS isn’t just a power module—it’s a glimpse at the future of electricity. 

[music] 

Kerrin: From highways to HVAC systems to high-voltage power, to…the close of another episode of The NREL Podcast. Tragic, is it not, Taylor? 

Taylor: But it’s always an exciting ride, and listeners we hope you are loving these updates here from NREL. 

Kerrin: Speaking of staying updated, you can always keep tabs on what’s happening at NREL through our social media: LinkedIn, X, Facebook, Instagram, and Threads. 

Taylor: You can also find these stories and more on nrel.gov. There’s a lot of ways to keep in touch. 

Kerrin: Absolutely, and we will be back to keep in touch with you on another episode of The NREL Podcast in two weeks. Thanks, everyone! 

[music] 

Kerrin: This episode was adapted from NREL news articles from September 2025 written by Aishwarya Krishnamoorthy, Julia Thomas, and Anna Squires. Our theme music is written and performed by Ted Vaca and episode music by Chuck Kurnik, Jim Riley, and Mark Sanseverino, of Drift B-C. This podcast is produced by NREL’s Communications Office.