Non-road Machinery Electrification: Best Practices in Battery and Charger Integration

This is a summary from the presentation of the same title by Mourad Chergui, Sr. Product Manager - Delta-Q Technologies and Andreas Paul, Director of Sales & Business Development EMEA - Inventus Power, at the Future of Electrification 2024 conference. Watch the full session here:

In this detailed discussion on the electrification of non-road mobile machinery (NRMM), Chergui and Paul shared comprehensive insights into the transitioning process from internal combustion engines to electric drivetrains. The session ranged from an overarching view of driving trends down to practical considerations for original equipment manufacturers (OEMs) seeking to successfully integrate cutting-edge battery and charging technology into NRMM.

Paul opened with a thought-provoking question: Why go electric? 

Recent advancements in electrification, while initially driven by the necessity of environmental considerations, now offer an increasing number of benefits over traditional internal combustion engine (ICE) vehicles. These benefits include:

• Reduced emissions
• Lower operating costs
• Decreased maintenance requirements
• Improved operator comfort and health

Paul noted that electric drivetrains also offer higher efficiency and durability compared to their internal combustion counterparts, with the potential of reaching over 90% efficiency in energy conversion compared to 35-40% for ICE.

These benefits will prove to be a boon for OEMs in areas with stringent regulatory and compliance standards. Numerous European countries in particular are driving ever-greener equipment, and manufacturers must position themselves appropriately should their customer base adopt stricter limits to carbon emissions.

Transitioning from the macro-level view, Chergui led an in-depth look at the logistics behind electrification. What challenges can OEMs expect when transitioning away from ICE? 

According to Chergui, OEMs must first re-examine their target users through the lens of electrification. While an electric drivetrain unlocks new efficiencies, it also brings new questions and considerations:

• What is the site infrastructure like? 
• Where will the power come from? 
• What relevant regulatory standards are in place? 

Chergui emphasized that manufacturers also need a solid understanding of the non-road machinery itself in terms of power requirements (both peak and continuous), duty cycles, and usage scenarios. These are all important questions that ultimately guide decisions regarding the final electrical system design, such as whether a full battery-electric or hybrid solution best fits customers’ needs.

The speakers also stressed the importance of selecting the right components and partners for the transition. Integration of off-the-shelf components where possible is recommended to avoid the costs and complexities associated with custom solutions. Collaboration with experienced suppliers who can provide comprehensive support and understand the intricacies of electric systems is crucial for a smooth transition. Such experts can provide valuable insights on more minute details, such as how environmental conditions (water, shock, vibration, etc.) affect battery performance and efficiency.

This led into a more granular discussion of design considerations for batteries and chargers. Since these technologies serve as the heart of electrified machinery, Chergui and Paul emphasized the need for a holistic approach to design and implementation. Both systems must be rugged, reliable, regulatory-compliant, and perhaps most important, compatible with one another. Rather than view the charger as an afterthought, both speakers noted the criticality of viewing battery and charger as one unit—clearly defining all design details well before moving towards production. 

According to Paul and Chergui, starting the design process early and maintaining clear communication between suppliers and manufacturers is key. The responsibility is not entirely one-sided in this regard. OEMs seeking custom designs with insufficient data can result in costly backtracking; conversely, partnering with suppliers who offer limited technical support can result in incompatibilities that could have been avoided.

Paul cited a prime example of this in the logistics of battery supply and delivery. Battery packs are classified as Class 9 dangerous goods, and OEMs with limited experience in electrified machinery may find themselves unexpectedly and abruptly limited when trying to expand into new global markets without the right certifications. To a similar point, Chergui stated that charging systems are ever-evolving, and a supplier offering products that have already been phased out may not be able to provide proper aftermarket support. 

Such scenarios emphasize the importance of teamwork from all angles of electrification. They also brought the conversation full circle—leading back to a macro-level analysis that can serve as guiding principles for OEMs seeking to electrify their fleets. Chergui reemphasized key takeaways: the importance of using shelf components over custom designs, viewing the charger and battery together as a single system, considering compatibility and testing early in the design process, and lastly, partnering with skilled, knowledgeable suppliers that will work with you through each phase of the process.

As this presentation demonstrated, transitioning to electric drivetrains in non-road machinery is not merely a technological upgrade, but a significant paradigm shift in how these machines are powered and maintained. Electrification offers numerous advantages such as improved efficiency, reduced environmental impact, and lower long-term costs. However, the transition also requires careful planning—with careful adherence to new regulatory standards, a strategic approach to component selection, and a holistic view of system design.

As electrification continues to gain momentum, it will no doubt present new opportunities for innovation and improvement in the non-road machinery sector.