EPTOs for Mobile Machines
ePTOs and Mobile Hydraulics
There are many benefits for vehicle manufacturers and OEMs who choose to adopt electric power take offs (ePTOs) as an alternative to the traditional engine PTO in an internal combustion engine. These benefits affect the application, the end-user, and the vehicle operating environment. From vehicle exhaust and emissions reduction to lessening the strain on the hydraulic system, there are many reasons manufacturers may choose to move to a hybrid vehicle model with an ePTO and combustion engine.
Whatever your reason, Cross Mobile Systems Integration Group can help. We take the time to learn your vehicle, manufacturing process, environmental requirements, and the needs of your future vehicle operators. When we understand how everything fits together, we’re able to create an ePTO system that is designed and optimized for your specific needs.
After working with hydraulic pumps and motors for decades, we have the experience and expertise required to work with you as an extension of your engineering department. That way, we can design, prototype, and implement the ideal electric power take off. Hydraulic and electrical power working together to charge batteries, run pumps, or reduce idling can be just the competitive advantage your industrial vehicle manufacturing process needs.
Lower Emissions, Higher Savings
At Cross, we want to provide the best products and services to all of our OEM and vehicle manufacturing customers. When you succeed, we succeed. And within the industrial mobile vehicle industry, changes are coming. They may be in the form of mandatory emission reduction or they may be in the form of market pressures for more environmentally sustainable heavy equipment.
No matter the reason, to keep an edge in an increasingly competitive market, it’s important to meet demands. The push towards hybrid and electric work vehicles can’t be ignored. That’s why we recommend that our OEM customers begin the process of work vehicle electrification and implementation of electric components as soon as possible.
Start the process today. Get in touch with one of our electric power take off experts to discuss how you can reduce emissions, meet mandates, and keep your production process competitive.
Hybrid Systems for Work Vehicles
Traditionally, the PTO output shaft has been a component of the internal combustion engine or vehicle transmission. That design means that the engine must be idling at all times during use. This produces excess emissions, is not fuel efficient, and decreases the lifespan of the heavy work vehicle over time. If only there were a way to reduce all of these factors while increasing long-term vehicle efficiency and productivity.
That’s where an electric power take off comes in. ePTO systems are made up of an inverter and an electric motor powered by a DC power source. In many cases, this is a battery. It allows the machine to run auxiliary loads from the battery instead of the combustion engine. Which eliminates the need for engine idling during PTO. This effectively reduces fuel consumption, vehicle emissions, and excess operating noise.
Integrating an ePTO into your hydraulic vehicle motor is a crucial step towards creating sustainable, hybrid vehicles. Whether your manufacturing process is facing outside mandates for greater sustainability or you just want to get ahead of the curve, ePTO systems are a big step towards lower emissions and greater sustainability. While full electrification may seem a ways away or unnecessary for a large machine, electrifying auxiliary loads can be good for both your vehicle manufacturing process and your bottom line.
Reduce Fuel Consumption
When the burden of auxiliary functions is taken off the internal combustion engine, it no longer needs to idle while powering them. Thus reducing overall fuel consumption.
Cut Your Emissions
Allowing an electronic power take off to control auxiliary functions cuts emissions from vehicle idling, letting manufacturers and end-users meet emission regulations or goals.
Lower Operating Volume
An ePTO also efficiently cuts operating noise, leading to less noise pollution. This increases safety for operators and other workers while meeting municipal noise standards.
Meeting Manufacturer's Power Needs
In most hydraulic systems, the PTO directly connects to the hydraulic pump. This provides the force the hydraulic fluid needs to get to any location throughout the system. When it gets to where it’s needed, a hydraulic motor or cylinder converts it into rotary (or linear) mechanical force.
While this seems like a straightforward system, power demands for hydraulic work vehicles vary tremendously. Depending on the application, we could be talking about many tens of kilowatts. Understanding these varying power needs is how we devise the optimal system for reducing them.
An idling vehicle can produce twice as much exhaust and emissions as an engine in motion. Excessive idling also results in greater wear on engine components, which translates to increased maintenance required over the vehicle lifespan.
With an ePTO, vehicles are able to meet their power requirements without excessive idling or engine strain. ePTOs electrically power auxiliary functions and equipment using energy that would have come from the internal combustion engine. Instead of hydraulic power, you have electrically powered auxiliary functions. That’s what makes the vehicle more environmentally friendly and sustainable while increasing lifespan and productivity.
Reduced Emissions
More Efficient Vehicles
Lower Air and Noise Pollution
Increased Vehicle Uptime
Less Maintenance
Improved Vehicle Lifespan
Creating Sustainable Industrial Vehicles
An ePTO system is made up of a battery pack, electric motor, hydraulic pump, and a smart electronic control system. These components work together to power auxiliary systems within a hydraulic vehicle that otherwise would be powered by an internal combustion engine. While shifting the power supply of these auxiliary systems may seem small, the effects it has on the machine and the environment around the machine are anything but.
When electrifying a fleet of vehicles, an ePTO system provides a higher environmental impact for each dollar invested than any other electrification solution on the market. In short, it creates a more sustainable vehicle.
But sustainability doesn’t just have to come in the form of environmental impact. Sustainability also comes in the form of lower repair and maintenance costs over time, as much of the stress has been taken off the internal combustion engine. Which leads to longer vehicle lifespans and less maintenance costs. As well as environmental sustainability.
Recycling
Utility Vehicles and Work Trucks
Cross Electric Power Takeoff Units
Components For Every Part of Your Electrification Project
Cross Mobile Systems Integration works with off-highway OEMs to improve their machine design and performance. Whether it’s hydraulics, electronics, controls or a full overhaul from ICE to electrified, Cross’s team of engineers works as an extension of our customer’s engineering team. We take the time to understand the unique requirements of each piece of mobile equipment and then design, prototype and build an optimized system for the machine.
AC Motors
Converts electrical energy into mechanical power, driving the machine with efficient, high torque, AC permanent magnet motors, suited for demanding applications. It enables smooth operation, reducing wear and tear while optimizing energy use in mobile equipment.
Regulates the conversion of DC power from the battery into AC power for the motor, ensuring smooth acceleration and precise control. Advanced inverters improve energy efficiency while supporting regenerative braking, feeding power back into the battery system.
Converts high-voltage battery power to low-voltage energy for auxiliary components, maintaining efficient power distribution. This ensures stable operation for critical low-voltage systems, such as sensors, control modules, and safety features, without compromising overall power availability.
Distributes low-voltage power to various electrical components, ensuring stable and reliable operation across the entire system. It minimizes electrical losses and supports easy integration of additional devices, enhancing overall machine efficiency.
Acts as the brain of the system, coordinating components to optimize machine operation, efficiency, and safety. It integrates sensors and communication protocols, providing real-time diagnostics and data logging for performance tracking.
Charges the battery system using external power sources, enabling convenient recharging without removing the battery. Onboard chargers ensure fast, efficient charging, supporting various voltage levels for flexibility in different environments.
Auxilliary Components
Supports essential machine functions such as pumps, fans, and lights, ensuring the seamless operation of subsystems. These components work harmoniously with the main powertrain to maintain functionality without compromising overall performance.
Stores electrical energy to power the machine, offering extended runtime and performance tailored to specific application needs. Modern battery systems are built with safety, thermal management, and scalability in mind, providing reliability in rugged environments.
Power Distrubition Unit (PDU)
Power delivery component for off-highway electric vehicles that manages the distribution of power from the energy source, such as a battery or fuel cell, to various critical subsystem loads such as traction inverters and on-board charging devices.
Ready To Electrify?
Our experts can work with your team to develop a complete mobile electrification solution to ensure that you have the right equipment, working together, to improve your machine performance and productivity.
Frequently Asked Questions
Basically, an ePTO system is an inverter and an electric motor powered by a DC power source (typically a battery). Auxiliary loads are then powered by this system instead of the internal combustion engine. This eliminates the need to idle the main engine during auxiliary operations, reducing fuel costs, engine wear, and air/noise pollution.
Integrating an electric power take off into your hydraulic vehicle is the first step towards creating hybrid and full electric powertrains. Further, decoupling auxiliary functions from the combustion engine allows for a smaller, more efficient engine. This saves on space, fuel consumption, and environmental impact. A more efficient engine also allows work to be carried out in the best yield zone.
The power demand from the ePTO can vary widely depending on the application. However, we have seen successes in ePTOs for construction, ePTOs for municipal work trucks, ePTOs for utility vehicles, and even ePTOs for the transportation industry. No matter your industry, if you’re using a hydraulic work vehicle, we can work with you to devise a solution to meet emission standards and optimize your vehicle.
The Electric Power Takeoff Company You Need
At Cross, we offer much more than just top-quality mobile machine parts and electrification services. We provide the experience and expertise our OEM and other equipment manufacturer partners need to succeed.
Why Cross Mobile Machine ePTOs?
A key feature we’re able to offer at Cross Company is an opportunity to bring your machine in for prototype development. With our Mobile Technology Center (pictured), we’re able to accommodate machines of almost any size. With a large staging lot, we can see the machine in action, making sure everything works as intended. We have been providing engineered solutions to our OEM partners since 2004.
This includes hydraulic system solutions, CAN based control solutions, and more recently, vehicle electrification design and integration. Whether you’re looking to integrate electric solutions into your existing architecture or develop a prototype for a unique job function, Cross can help.
A key part to any electrification project is the power required to run a machine, and managing that power. If you are interested in learning more about how Cross can help make your equipment operate more efficiently, contact a team member today!
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