This presentation will take the audience through Frost & Sullivan’s long-term forecast on OHV electrification trends at the global level. It will present a technology roadmap for OHV hybrid technology toward 2030 and beyond, introducing key drivers of electrification, and discussing market and technology trends and the latest product advancements by OEMs. An off-highway equipment demand forecast will be revealed, predicting a brighter future for electrified machines. The market is expected to grow more than twofold by 2025. By 2030, the majority of OEMs will have ventured into the electrification domain.

This presentation will review Doosan’s strategies for electrification with 48V mild/full hybrid and e-powerpack – the Intelligent Hybrid Powertrain. This will include the concept and architecture, and results of development (simulation, bench and vehicle test).

Volvo Group has shifted to electromobility throughout its business – from trucks and buses to marine and construction equipment. This presentation will discuss the market-leading innovation journey of Volvo CE as the company moves from prototype machines and research projects through to an industry-first commitment to stop the development of diesel-based compact machines and the launch of their electric counterparts. It will address the challenges of adapting electromobility to the market, and also the successes that have emerged from customer trials, including the debut of the ECR25 Electric at the RHS Chelsea Flower Show in the UK.

Manitou Group unveils its strategic ambitions on alternative energies by explaining how R&I teams are working together to give the best answer to their customers’ expectations. Look at how far the Manitou Group has already come and how the next steps of its program are totally integrated in the company’s CSR 2025 Roadmap, which is obviously oriented on a low-carbon trajectory.

Off-road vehicles contribute over 2% of global greenhouse gases. High energy use, tough environments, linear motions and cost pressures make electrification difficult. But there is low-hanging fruit: existing off-highway hydraulic systems waste 50-70% of the engine’s useful energy. Digital Displacement technology offers the industry a new roadmap to deliver dramatic efficiency improvements in hydraulic systems, reducing emissions and fuel costs while increasing productivity. Focusing on excavators, the presentation will show the latest results on an evolutionary path from today’s analog hydraulics toward fully digital hydraulic systems that will reduce fuel consumption (or battery size) by 50% or more.

The motor controller is a key component in the industrial vehicle electrification process. It has to be able to efficiently drive an electric motor and allow connectivity with other drivetrain devices. Electric motor technologies have changed over the last few years, and a modern motor controller must be able to drive all possible technologies. An auto-tuning feature reduces the commissioning and test time and optimizes system efficiency. Furthermore, if the motor controller includes dedicated and advanced control functions, the effort involved in developing the vehicle control unit control system is reduced. Power electronics device evolution allows a reduction in controller size and achieves more efficient power conversion. The presentation will go through motor control technologies and features available in DMC controllers, showing how they cover the requirements for the electrification process.

Rare earth magnets (REM) have cost volatility and availability issues that affect the industries using them. High efficiency, silent operation, cost-effectiveness, energy recovery and performance are key factors in next-gen IVT applications. Synchronous reluctance motors (SRM) are the low-torque ripple solution, removing REM dependence. Regenerative electrohydraulic application driven by REM-free SRM is achievable through integrated engineering of electromagnetic, mechanical vibration reduction and hydraulic unit design. A pump-motor unit based on no-noise two- (Continuum) or four- (Continuum 4Q) quadrant technology creates a highly efficient, compact and regenerative simplified electrohydraulic design. New design features include energy recovery, no noise, low vibrations, and high dynamics and power density.

Internal permanent-magnet synchronous motors (IPMSM) offer high power density and therefore can increase the driving range of battery-supplied vehicles. However, they are technically complex, and commissioning requires detailed knowledge of the motor parameters. REFUdrive has addressed this issue with outstanding drive control methods. The talk is focused on operating these motors utilizing online parameter identification based on Kalman filtering to become independent from the technical database. We will give insight into how to push the efficiency, performance and ease of use to the technology limit, and how our customers can benefit from that.

The presentation will discuss the root causes of shaft voltage, the impact on the motor bearings and EMI/RFI, possibilities to proof and mitigation strategies.

Batteries need to be tested during R&D and also during the production process to ensure high quality and safety. Batteries store a lot of energy, which needs to be charged and discharged several times during cycling tests. Classical discharging by resistors causes very high energy losses. Energy recovery to grid by individual converters still has certain losses, although they are considerably reduced. A good alternative is Gustav Klein’s Multi-Channel Infeed Testing System. This four-channel testing system allows internal energy recovery, which reduces the losses in power electronics.

This presentation will give an overview of the global off-highway vehicle market and the forecast for low- and zero-emission solutions. This will include a discussion about our approach of looking at vehicle application/duty cycle, and how this impacts the trend toward electrification. The speaker will also offer an insight into the industrial Li-ion battery market, forward production and pricing trends, and the impact on off-highway electrification uptake. An overview of urban low- and zero-emission zones, and how these are driving early adoption, will also be given. There will also be discussion of the impact of on-highway commercial vehicle market electrification, including technology transition/migration and a detailed focus on China, and how new policies and company direction will affect the global market.

California has just launched the Clean Off Road Equipment (CORE) incentive program, managed by Calstart and modeled on the successful HVIP on-road incentive program. CORE targets the leading equipment segments most ready for zero-emissions operations (terminal/yard tractors, TRUs, GSE, cargo lifts and other segments) and provides funding to cover the incremental cost and infrastructure to help operators more quickly shift to cleaner equipment. Calstart will highlight how the programs work, the status of the eligible technologies, future equipment categories that could be included, how this will support the global market supply chain, and the applicability of this program to other regions.

Electrification of construction machinery can offer a significant positive impact on operating costs and the environment. So why aren’t we seeing many more electrified construction machines in the field? The presentation will describe Danfoss’s strategy to support customers in overcoming the challenges of electrifying construction machinery. It will illustrate how the company is utilizing the different technologies and capabilities in its organization to develop solutions for zero-emission construction.

It is not only efficient components that offer high energy-saving potential. It is also necessary to consider the system, the drivetrain and the duty cycles. This presentation will show different approaches.

With governments worldwide seeking to reduce GHG emissions, road transport is being targeted to shift to net-zero emissions. However, changes to the supply chain and energy system will disproportionately affect non-road mobile machinery manufacturers and end users, who benefit from close links to heavy road transport. The presentation will assess the benefits and challenges in the adoption of net-zero in the agricultural, construction and materials handling segments.

This paper presents a modular and scalable electric drive platform for NRMMs. The platform is part of a research project called Muffel+ funded by the German Federal Ministry of Education and Research. The platform can be integrated into different machines with different performance classes. The modular and scalable electric drive platform will be demonstrated using the example of a hybrid multifunctional vehicle. The research project includes drive motors, power electronics and an intelligent control and cooling concept for the powertrain. The platform offers the possibility to integrate compact function-integrated components, which are produced by additive manufacturing.

Many drivers are in favor of electrification: low-emission zones, workplace emissions regulations, Stage V below 19kW. System simulation is a key asset for exploring electrification, by enabling the identification of electrical system requirements, supporting the pre-sizing of electric motor, power electronics and battery, and addressing the validation of components development versus system requirements (autonomy, aging, thermal management, power).

Carraro defined its sustainability path by looking at the vehicle and drivetrain electrification as a significant opportunity to limit emissions without reducing productivity and efficiency. We’ll show our new hard mild-hybrid tractor starting from the bench and the digital simulation based on the integrated made-by-Carraro components. This concept can support ICE overloads, leading to engine downsizing and geometry reduction without losing performance. Economic and ecological sustainability is ensured thanks to fuel consumption minimization and CO2 emission reduction. The session will show field test results and cost comparison with a traditional 100Hp ICE tractor.

Mobile container handling has been a diesel territory for decades. But times are changing and so is technology. Nowadays, a range of solutions for powertrains is available. Among many strategies, electrification is a key strategy for Hyster. This presentation will discuss the company’s electrification strategy for container handling solutions with a focus on hydrogen-fuel-cell-powered machines. It will also address changes and impacts on planning and infrastructure brought about by electrified machines.

What are the advantages of a parallel hybrid and a serial hybrid system? In what kinds of situations do serial hybrids with hydraulic propulsion drives have advantages and when are electric-mechanical solutions better? Parallel hybrids, especially in combination with AC induction motors, have huge advantages for some applications.

This presentation compares current sensor technologies and their influence on powertrain performance. It also gives an outlook on the next sensor generations with digital interfacing ability for autonomous driving in a safety-integrated manner.

Littelfuse is more than just fuses: it offers a wide portfolio of high-current relays, control electronics, current sensors, fuses and power distribution modules for commercial vehicles in low- and high-voltage systems. With this, the company is able to integrate the inner core of single components into one product and thus offer system savings.

Technology related to NRMM electrification has been a research topic in science for a long time. Companies have been developing proofs of concept and prototypes. Today, many OEMs are moving toward electrification in serial production machines. Technology has to bring clear benefits in operator experience, CO2 reduction, productivity, safety and total cost of ownership for customers. This case study includes simulation-based technology development of a 200kW power class hybrid-electric non-road mobile machine (NRMM) considering sustainability in the supply chain, manufacturing and lifetime operations.

Learn more about maximizing the efficiency of off-highway machines with thermal management, and gain up to 25% range. The Webasto standard off-the-shelf or customized battery and thermal management systems offer you a complete system solution.

Picking the right battery charger is a critical design choice for electrified vehicles. Your industrial vehicle needs an efficient and robust onboard charging system that can withstand harsh environments and use. A modular battery charging system has advantages over a single bulky charger, including packaging and installation flexibility, reliability and total cost of ownership.