Volvo Group has shifted to electromobility throughout its business. This presentation will discuss the market-leading innovation journey of Volvo CE as the company committed to stop the development of diesel-based compact machines and launch their electric counterparts. It will address the market introduction of the ECR25 Electric, and also the successes that have emerged from customer trials.

The world is going through a revolution to address the complexities of climate change. Transportation as an ecosystem is one of the major leaders in the move to decarbonization and net zero. How can you accelerate and monetize the electrification of your fleet? This presentation will explain how Hitachi is supporting transport companies both on- and off-road to accelerate their decarbonization journeys using smart technology solutions and artificial intelligence.

Decarbonization of the heavy-duty sector is essential in the drive toward net-zero greenhouse gas emissions. Full electrification may be suited for some applications but the potential to move swiftly to a zero-carbon solution by developing existing technologies, using low- and zero-carbon fuels, may provide a faster reduction in emissions. This route carries advantages by leveraging existing manufacturing infrastructure and mature technologies. This study examines a potential pathway to a zero-carbon outcome, transitioning away from diesel, via biogas, to hydrogen. Hybridization minimizes raw fuel consumption, making best use of renewable fuels. The study investigates the enabling technologies and infrastructure required.

In line with Vision Zero, one of ZF’s objectives is to reduce emissions to zero. Therefore, the group is developing intelligent system solutions for the construction site of the future, all bundled under the eTRAC range. The presentation will give insights into ZF’s roadmap to zero-emission drivelines, explaining which projects are currently being worked on, which conclusions can be drawn from series products launched earlier and which products are to come in the near future.

Based on Calstart’s forthcoming white paper, this presentation will discuss near-, medium- and long-term applications for off-road electrification and the pathways to achieve scale in those segments. Lessons from California’s first year of the Clean Off-Road Equipment (CORE) voucher incentive project point the way forward for zero-emission applications across sectors, with opportunities for technology transfer and infrastructure solutions.

Electrification of construction equipment is a major goal to reduce air pollution, the emission of CO2 and noise. In the meantime, construction companies are facing very demanding requirements in terms of cost and productivity. The WATTELSE project is financed by the European Commission to meet to these needs with an innovative turnkey solution for OEMs: a versatile, modular, lithium-ion battery system to provide OEMs with a tailored solution capable of maintaining the productivity of a standard machine. The battery maintains full power capacity for an entire day of work in the rough environment and climate of a construction site.

Battery-electric vehicles in off-highway applications have many positive factors, especially for underground and mining. The biggest challenges are tough operation conditions and providing as little maintenance as necessary, ideally before failure occurs. Downtime related to failures and efficiency problems is a high cost not only in financial terms but also in terms of customer opinion. This sometimes slows down the process of switching to the electrification of off-highway machinery. The presentation will reveal the results of a study on the application of PM to battery thermal management systems in such applications.

The presentation will offer some insights into how to speed up electrification in the construction machinery area. Based on a successful customer project, it will how Webasto’s modular off-the-shelf battery system can be easily integrated into various kinds of construction vehicles.

The pace of electrification has increased dramatically. Almost every sector is pressured with tremendous emission reduction goals, up to complete elimination in inner-city applications. While compactness and high efficiency are a precondition, modular motor concepts are also needed to cover complete vehicle series and reduce the lead times of prototypes and series projects. This presentation will give an introduction to the Engiro approach, to cover a power range of mobile applications from 10-400kW and 48-800V for traction and auxiliary drives. Case studies from agricultural, construction and truck applications will point out the flexibility of this approach.

The presentation will discuss some comparative studies that have been carried out at Lenord+Bauer with classic resolvers, as found in many drivetrains, and with Lenord+Bauer’s new inductive sensor series. In future developments, developers and designers must take into account that data sheet specifications very often refer to idealized assembly, and that in practice there can be deviations in assembly and thus deviations in the data-sheet values.

When designing an e-vehicle, you choose the key components of your powertrain – battery pack, motor, inverter, charger, etc – but then come the challenges: how to efficiently interconnect these components and ensure the integrity and safety of your HV network? During this workshop we will present our solutions for power distribution units based on PCB technology (60V DC up to 1,000V DC). We will discuss the key characteristics to take into account for a safe design, and explain how PCB and Press-Fit technology can improve PDU design. We will also introduce an innovative concept to increase flexibility and agility while reducing time-to-market and qualification effort.

A wide variety of applications such as construction, agriculture, forestry and mining are demanding a rapid response to tight emissions regulation. Work is ongoing to overcome the challenges of improving off-road machinery work; however, it mostly concentrates on improving the drivetrain – working hydraulics (implements) are not taken into consideration. Conventional working hydraulic systems are valve controlled and suffer from high metering losses, which lead to overall system efficiency about of 21%. Now it is time to take further steps to achieve 50% less energy consumption and improve efficiency by 200% of the whole system by applying novel concepts instead of conventional ones. Utilizing a more-electric architecture of multiple power sources in each working zone can achieve energy savings and works with a power-on-demand approach. The presentation will discuss the results of the implementation of the Zonal concept investigation by simulation and experiments on study cases of full-size off-road vehicles such as excavators and wheel loaders.

CO2 emission targets have increased during this decade, and construction machines are still excluded from harsh regulations – but how long will this last? We all know that hydraulic valve control was developed for ICE-driven machines 60 years ago – its principle creates throttle losses, and energy recuperation is not possible. The new HELAX eliminates throttle losses and recuperates potential energy. Using a highly efficient hydro unit enables the lowest losses. Not only is it highly energy-efficient but it also provides very precise controllability. Thus, we can use the new opportunities offered through electrification by managing energy from several sources and using different control concepts.

Electrification and hybridization have dramatically reduced engine noise from industrial vehicles, making hydraulic circuit noise predominant. Variable displacement pumps can further improve operator comfort but can be inefficient. The Elika gear pump has been co-developed with the faculty of engineering at the University of Bologna, using helical gear technology. This technology delivers low noise with high efficiency across a high range of speeds and is particularly efficient when coupled with VFD (variable frequency drive) brushless motors. Recent tests at the Marzocchi R&D lab demonstrated flow from 1 l/min to 20 l/min using the same displacement and maintaining high volumetric efficiency (>90%) throughout. This presentation will demonstrate how recently discovered additional benefits of helical gear technology can increase efficiency and reduce cost when deployed in electrified powertrains.

The presentation will focus on the electrification of mobile machines. It will propose a process to succeed in electrifying a compact machine, focusing on the key input information to collect. It will also introduce the concept of electrohydrostatic zero-emission systems and detail the benefits of such solutions for OEMs and end users.

The Husco off-highway division has taken the differentiating solenoid technology used by Husco Automotive and utilized it for the off-highway market to enable digital control of a variety of functions on next-generation electric, hybrid and alternative-fuel machines. The presentation will provide a summary of the unique solenoid mechanism, give details of the key performance characteristics and demonstrate how the technology is enabling efficient digital control on off-highway transmissions, steering, braking and autonomous control systems.

This presentation explores the differences and similarities in the construction and control of the three main traction motors – induction machine, interior permanent magnet and synchronous reluctance. The field-oriented control of these motor types is outlined and it is shown that the motors are interchangeable when it comes to control. Model-based design techniques to create and test the embedded control of the complete traction motor drive are explored, with some surprising results regarding efficiency and total costs.

The already known electric drive platform is modified and used as a basis. An evaluation of the drive platform by means of a decision matrix is carried out. Which parts are suitable for additive manufacturing and why? The whole process is illustrated by means of an example (cooling components inverters).

In the context of current efforts to reduce CO2, pollutant and noise emissions, container transport within ports or terminals has to be considered. A system solution for battery-powered terminal tractors (TT) to replace diesel-powered tractors has been developed within the ZETT – Zero Emission Terminal Tractor project, taking into account ecological and economic requirements. In this context, the Institute for Automotive Engineering is investigating how the design of the powertrain and the charging infrastructure can be realized by coupling fleet and longitudinal dynamics simulations. The aim here is to enable operation without restrictions and at the same time to prevent over-dimensioning of the powertrain components – especially the battery.

Electrification is arriving in the agricultural industry and is seen as the holy grail for reducing CO2 emissions and increasing sustainability. Population growth and prosperity are still the main drivers for GHG emissions. Future pathways for renewable energy and fuel production need to be developed and upscaled. To get a clear picture of the sustainability of different propulsion systems, a cradle-to-grave evaluation was undertaken for four different powertrain systems for a standard multi-purpose tractor. Optimizing for low CO2 – considering also production – requires rethinking the configuration of the propulsion system.

Electrification is a technical challenge for industrial vehicle manufacturers. With so many potential use cases, choosing and applying the right battery technology is crucial to optimize daily operations. Saft has over 100 years of expertise in industrial batteries. In this presentation, the company will explain the prevailing lithium-ion technologies and give its view on future developments. Attendees can discover which chemistries and systems will best match the needs of their applications.

The presentation will outline different concepts for thermal management of electric machines. This will include a standardized concept to ensure short development times and reduced development and application effort. The presentation will be illustrated with real use cases and real operation data.

A modern approach to electric motor control implies the availability of advanced features. Efficient autotuning is a basic requirement but it is not enough to ensure successful controller commissioning. Sensorless control of actuations and auxiliary devices other than traction is leading to more reliable and cost-effective electrification. Furthermore, pandemic-induced travel restrictions force the controller manufacturer toward advanced software tools for easy commissioning that can also be done remotely. Controllers must support the most common field buses in a smart, configurable way. The presentation describes these features and explains how DMC controllers implement them.

With the global trend toward the development of electric vehicles continuing to accelerate, there are new challenges for engineers to solve. One of these problems is range, which has significant differences between real and theoretical range. The overall efficiency of an electric vehicle depends on how the vehicle is used. It can be improved through measurement and analysis. Quantifying the conversion of direct current from the battery to alternating current using an inverter is particularly challenging. These produce a frequency-modulated, non-sinusoidal, transient waveform through pulse-width modulation. A case study is used to present AC power analysis in digital post-processing.

Software and electronics play a key role in future heavy machine electrified powertrains. System integration considering safety, performance, lifetime, efficiency, total cost of ownership and machine bill-of-material cost is a complex challenge for OEMs. The amount of electronics and software is increasing significantly, offering multiple benefits for OEMs and end customers. Epec control systems and electric powertrain components give customers the freedom to select any third-party electric motor, battery or other key component.

The importance of decarbonizing is a well-recognized topic. Electrification of working machines is seen as a way to reduce not only CO2 but also other local emissions on the construction site. This creates a demand for charging solutions. While other electrified equipment such as electric cars, trucks, buses and electric ferries have their own industry-preferred charging infrastructure already agreed, in the working machine industry there are multiple possibilities being explored. In this presentation, we go through some options and explain how Danfoss can help industrial vehicles to electrify the future.

In the 1960s the transition from rope excavators to hydraulic excavators was driven by improved controllability and functionality. We can see a similar disruptive situation now starting with the electrification of drivetrains in mobile working machines. Aradex takes part in this game-changing process using virtual sensor technology used for all kinds of electrified drivetrains. Without additional sensors we can create high-resolution data for speed and torque in real time and make the data usable for data mining and higher performance of drivetrains. We will show the first impressive measurements and some possible applications for working machines.

Driven by increasingly stringent global regulations and changing consumer requirements for greener solutions, off-highway vehicle manufacturers are under increasing pressure to make their electric and hybrid powertrains even more efficient. Hella specializes in innovative lighting systems and vehicle electronics and has been an important partner to the automotive industry and aftermarket for more than a century. Thanks to many years of experience in large-scale production in the automotive industry, the firm can transfer these technologies to manufacturers of small series. This presentation will take you through energy management on the basis of case studies. The two most important products for the off-highway industry – the intelligent battery sensor and the DC-DC 48V/12 V converter – are presented in detail.

Advancements in battery performance and charging technologies are contributing to the shift toward electrified compact mobile machinery. Components such as a high-voltage battery, an electric motor, an inverter, a DC-DC converter and an onboard charger are required to build a high-performance electric vehicle. However, component requirements can vary depending on the machine type. Learn best practices for system integration, and how the battery and charger can affect the vehicle’s performance in this presentation.

This presentation explores the challenges and lessons learned in delivering a robust and reliable solution, unlocking the full potential of hybridization/electrification. With tangible examples of how to transition from an existing combustion-engine-driven solution to an electric or hybrid machine, this presentation provides an inclusive look at available technology and explains how to select the ideal solution for your mission profile. Due to rapid changes across all market segments Twin Disc has invested and developed new solutions to become a dominant hybrid and electrification solution supplier and system integrator. Product experts are currently working with many OEMs to help them achieve their electrification goals.