This is a summary from the webinar of the same title by Rod Dayrit, Global Director of Business Development, Charging Solutions, at ZAPI GROUP.
As the world shifts toward electrification, industries are under increasing pressure to adapt toward a sustainable future through decarbonization—and off-highway mobile machinery (e.g. construction, agriculture, outdoor power equipment) is no exception.
While the latest innovations in charging technology play a key role in driving adoption, overall, this sector is seeing gradual, but widespread electrification.
For legacy OEMs seeking to electrify, this slower pace is not a downside. Rather, as Rod Dayrit explains in the webinar, it represents an ideal opportunity for development teams to benefit from the mature electric technologies of parallel industries—such as advanced charging solutions used in material handling operations.
It is no understatement to say that off-highway electrification hinges on charging technology, addressing the unique demands of diverse sectors. Dayrit dedicated much of the webinar time delving into four specific technologies underpinning the latest developments.
Rather than a singular technology, Dayrit observed that electrification follows a three-phase generational model. The trajectory of these phases points to a future of fully integrated electric drive trains, defined by:
These closed-box charging solutions represent the industry’s future state, and Dayrit noted the sector is indeed trending in this direction. However, he also cautioned OEMs on the trade-offs of such integrated models, delving into an analysis between flexibility and cost efficiency.
While urging a deliberate approach, Dayrit further acknowledged that integration is non-negotiable for certain components, especially chargers.
Integrating on-board chargers is necessary to leverage existing electric vehicle supply equipment (EVSE). This broadens recharging options for OEM machinery across various settings, from public EV stations to basic AC wall plugs.
Rapidly growing fast-charging infrastructure further expands charging accessibility, reducing logistical barriers to industrial electrification. Next-generation charging solutions already support on-demand charging for construction equipment, with similar options anticipated for other off-highway applications.
According to Dayrit, materials like gallium nitride (GaN) and silicon carbide (SiC) semiconductors promise substantial efficiency gains in power electronics.
For example, GaN outperforms traditional silicon by a wide margin:
These advantages position GaN and SiC as a stronger (though less mature) alternative, especially in high-powered off-highway applications.
A modern BMS maximizes the return on investment of an electrified machine’s single most expensive component: the battery. Dayrit expanded on this point by highlighting several specific advantages of an intelligent, integrated BMS:
Leveraging BMS—along with a charger tailored to the application—thus enables OEMs to ensure the battery operates at peak performance.
Dayrit summarized these advancements in charging technology with an insightful look into where system integrators fit into the equation—as comprehensive partners in the electrification journey.
As the industry shifts towards integrated solutions, strategic partnerships across all electrification technologies, from battery supply to charger integration, are essential for OEMs to:
Closing the webinar, Dayrit re-emphasized the primary theme: Electrification in off-highway applications is still in its infancy. Yet OEMs seeking to electrify can learn much from mature ecosystems—the challenges, successes, and failures—to develop iteratively tested designs unique to their vertical.
OEMs will continue to shift towards integrated solutions. In fact, they are encouraged to do so.
By partnering with electrification experts such as ZAPI GROUP, whose experience spans historical insights and cross-industry expertise, OEMs can more easily transition from self-designed solutions to sophisticated, integrated ones.
With the guidance of such seasoned partners and a discerning approach to integration, OEMs are well-positioned to harness emerging innovations, powering progress at every touchpoint.