Low-Voltage AC Motors for Equipment Electrification

Electrification with AC Motors for Mobile Systems

Performance, efficiency, and reliability are all necessary considerations in electrification projects for mobile work machinery. This is especially true when transitioning from internal combustion engines (ICE) or traditional DC brushed motor systems.

At Cross Company’s Mobile Systems Integration Group, we specialize in delivering expertly tailored AC motor solutions designed to meet the unique demands of your particular application.

Why Use AC Motors?

AC motors have become the go-to choice for equipment electrification projects due to their high efficiency, longevity, low maintenance requirements, and wide speed and torque ranges.

Because of limited space on mobile equipment, and the cost of batteries, you want and need the most efficient motors when electrifying your equipment. That, along with their longevity and low maintenance requirements, in most cases, make them the right choice for your machine.

Low Maintenance

Unlike DC motors, AC motors are brushless, eliminating wear and tear components. There is little to no maintenance required for these motors. Less service means less cost for both you and your customers.

Increased Longevity

Within the application itself, AC motors are simpler in operation and are able to last significantly longer under strain due to a decrease in moving parts such as brushes seen on DC motors. Additionally, the paired inverter will monitor the temperature sensor embedded in the motor and reduce power delivery if the motor reaches a high temperature set point, preventing any thermal damage.

Higher Efficiency

AC motors are typically able to achieve 95% efficiency compared to roughly 80-85% for DC motors. This translates into extended battery life, less heat generation and reduced cooling needs, and increased duty cycle for mobile systems.

Wide Speed and Torque Range

Both asynchronous (induction) and synchronous (brushless permanent magnet or synchronous reluctance) AC motors offer high flexibility across a broad range of speeds and torque requirements. By being able to control these motors precisely by either using speed or torque commands, you gain the ability to have very precise control over your machine function.

nidec ac motor

Synchronous vs. Asynchronous AC Motors

When comparing synchronous versus asynchronous AC motors, there are several considerations to be made based on your specific application. Factors like space claim, vehicle size, job function, cooling needs, travel distance, cost, as well as others, can help determine the right motor for your machine. Cross Company and our MSI group can help you select the right motor for your needs.

Synchronous Motors – Extremely efficient, making them ideal for electrified, battery-powered systems. This efficiency reduces wasted energy, extends battery life, and minimizes heat production within the system itself.

Asynchronous Motors – Cost-effective and easy to manufacture, making them an ideal choice for budget-sensitive projects

Why Choose Cross Company For Vehicle Electrification?

Electrification is about more than just selecting the right motor. It’s about designing complete systems that integrate seamlessly with your application. This is where Cross Company and our Mobile Systems Integration Group excels. We take a comprehensive approach to your machine to determine the right components and systems, source those products, and ensure that the different components work together seamlessly.

Our offering is more than just a single AC motor. We also provide

Comprehensive System Design

From job function to control requirements, we take everything into account. We also ensure compatibility between motors, inverters, and other components for a cohesive solution

Extensive Vendor Network

We utilize our wide range of vendors to source the most effective components and systems for the specific needs of your application.

Expertise in Tuning and Integration

With over five years of experience in electrification, we’ve tested and fine-tuned various motor-inverter combinations. That means we’ve already solved many common integration issues that may arise.

Tailored Testing for Optimization

Whether it’s downsizing or optimizing for efficiency, we perform rigorous tests to ensure that your system is able to consistently meet performance goals.

Support for You

Selecting the right components for a machine is a complex task. From product selection to system integration, we guide you through the entire process

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.

Low-Voltage AC Motors for Equipment Electrification 1

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.

Learn More →

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.

Learn More →

Inverters


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.

Learn More →

Low Voltage DC/DC Converters


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.

Learn More →

Low Voltage Bus


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.

Learn More →

Machine Controller


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.

Learn More →

Onboard Chargers


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.

Learn More →

ePTO


Cross Company's Electric Power Take-Off (ePTO) solutions provide reliable and efficient electric power for mobile equipment, reducing reliance on traditional engine-driven PTOs. Ideal for applications requiring auxiliary power without engine idling, ePTO systems improve fuel efficiency, decrease emissions, and lower operating costs. without compromising overall performance.

Learn More →

Batteries and Battery Management Systems


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.

Learn More →

Motor Driven Gearbox


Cross Company's motor-driven gearboxes offer precise and efficient power transmission for mobile and industrial applications. These gearboxes are designed to work seamlessly with electric motors, providing optimized torque and speed control for demanding tasks.

Learn More →

rh&m go-for-digger

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.

The Cross Company Difference

At Cross, we don’t just provide components. We deliver solutions.

Whether you’re looking to replace an internal combustion engine, upgrade from DC brushed motors, or optimize your existing system, we provide a whole-system approach that prioritizes efficiency and performance.

Ready to electrify your mobile system with the right AC motor solution? Contact us today to discuss how Cross Company can help power your next project.

Low-Voltage AC Motors for Equipment Electrification 2

See How A Solution From Our Mobile Systems Integration Group Can Benefit Your Operation

Contact our Team

Hang Tight! We're Searching... Searching... Searching...

We’re looking through thousands of pages to find the most relevant information.

In the meantime, enjoy these fun facts…

Did you know… Cross Company is an ESOP (Employee Stock Ownership Plan). Our ESOP started in 1979 and as of 2006, we are 100% employee-owned! Learn more about our ESOP and how that benefits both team members and our customers.
Did you know... the precision measurement group at Cross was founded in 1939 by our current CEO's grandfather, Jim King. That's a whole lot of calibration!
Did you know... A fingerprint weighs about 50 micrograms. We know, we weighed it! The residue left from a finger can actually make a difference in weight results which is why we wear gloves when we calibrate weights. For reference, a sheet of paper is about 4.5 grams, that’s 4.5 million micrograms.
Did you know… Cross Company has grown significantly since our start in 1954. Over the years we've acquired 26 companies! Today, our five groups have expertise in everything from industrial automation to precision measurement, and industry knowledge going all the way back to 1939.