Low Voltage Onboard Chargers
Onboard Chargers for Mobile Equipment
Onboard chargers for electric mobile equipment are integrated charging stations designed to be mounted directly on and travel with the machine. Unlike standalone chargers that require the machine returning to a fixed charging station, onboard chargers are able to charge equipment anywhere with access to 120V or 220V AC power. This makes them highly flexible and particularly useful for off-highway and over-the-road machinery operating in diverse or remote locations.
Onboard chargers are a critical component in mobile equipment electrification, providing flexible and efficient charging solutions. These ruggedized systems are designed specifically for integration into mobile work machinery, ensuring reliable battery charging wherever line power or AC supply is available.
At Cross Company’s Mobile Systems Integration group, we can work directly with you to source and prototype an onboard charging solution for your application. Contact one of our experts today to learn more or to start the process.
Features and Benefits of Onboard Chargers from Cross
Power Ranges
Onboard chargers are able to deliver power outputs ranging from 350 watts to 3.3 kilowatts for standalone applications, with scalable options up to 10 kilowatts when chargers are used in parallel
Battery Compatibility
Onboard chargers provided by Cross Company are compatible with a wide range of battery chemistries. This includes lithium-ion and lead-acid (wet, AGM, and gel). This makes them flexible in application
Rugged Construction
These chargers are specifically engineered for demanding environments. They boast IP67-rated enclosures to protect against dust and moisture, offering protection even in off-highway environments
Integrated DC-DC Converter
Provides auxiliary power for operating vehicle accessories, reducing the need for additional components.
EV Charging Station Interface
Compliance with SAE J1772 and IEC 61851 standards allows for charging from standard EV stations across North America and Europe.
Enhanced Safety
Protection against over-voltage, over-temperature, and short circuits ensures safe operation.
When To Use An Onboard Charger
Onboard chargers are ideal for:
- Equipment with onboard battery packs requiring mobility and flexibility.
- Applications with space constraints where centralized charging stations are impractical.
- Machinery operating in confined spaces, such as warehouses, or in remote locations where access to charging stations is limited.
- Over-the-road equipment, such as forestry or construction machinery, that needs to maintain charging capabilities while in transit.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
Why Use an Onboard Charger?
There are many benefits to using an onboard charger in your mobile machine electrification project. Some of these benefits include flexibility, rugged design, and battery optimization
Flexibility
You’re able to charge your equipment anywhere with line power access. This reduces downtime, allows you to charge the batteries whenever you have down time, and increases operational efficiency
Rugged Design
Made for mobile and off-highway use, onboard chargers feature durable enclosures, built-in cooling systems, and ingress protection
Battery Optimization
Advanced charging algorithms communicate directly with the battery management system to ensure proper charging, enhancing battery life
See How Cross Mobile Systems Integration Can Help
A key component in mobile equipment electrification is choosing and managing the power you need for optimal performance. With Cross Mobile Systems Integration, you get a partner dedicated to delivering reliable, efficient, and innovative power solutions for your specific application. Whether you’re integrating electric components into an existing hydraulic system or developing a fully-electrified prototype, our team is here to help.
If you have an onboard charging application and need expert guidance, Cross Company’s Mobile Systems Integration Group is here to help. Our team specializes in integrating onboard charging solutions tailored to your equipment’s needs. Contact us today to discuss your project and discover the best solution for your electrification requirements.