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Industrial Vehicle Electrification

Electrification for Mobile Work Vehicles

Vehicle electrification is the process of powering a hydraulic work vehicle with electricity. It involves replacing vehicle components that operate through an internal combustion engine with components that operate through electricity. Typically, this is done through creating a powertrain and auxiliary systems that are powered by on and off-board charging systems. At Cross Mobile Systems Integration group, we perform that service for mobile hydraulic work vehicles.

Fleet managers, OEMs, and other vehicle manufacturers are increasingly considering the impact that traditional internal combustion engines have on their mobile machinery. From emission reduction to saving on fuel costs, there are a variety of reasons many within the mobile work machine industry are moving away from gas-powered models and towards electrification. At Cross, we provide vehicle electrification services for OEMs and vehicle manufacturers to meet emission standards, to provide long-term value to end users, and to create a competitive market advantage for their product.

If you’re manufacturing mobile hydraulic machines with an internal combustion engine but thinking about making the switch to electric powered vehicles, we can help.

Declining cost of batteries

Increased market advantage

Reduced fuel consumption

Optimal space allocation

Targeted emission reduction

Future-proofed manufacturing

Making the Switch

As electric work vehicles are becoming more prevalent, many newer vehicle manufacturers specializing in EVs are entering the scene. This has proven to be a challenge for many traditional OEMs. How do you compete with these newer manufacturing companies while staying loyal to the traditional hydraulic/ICE model?

The answer is partnering with Cross Mobile Systems integration group. We’ve worked with countless OEMs over the years. We’ve learned the ins-and-outs of the mobile vehicle manufacturing industry. And we can confidently say that partnering with the right vehicle electrification company is the most crucial step a manufacturer can take to maintain a competitive advantage in a rapidly electrifying market.

If you’re thinking about making the switch to electric industrial vehicles, now is the time. Cross operates as an extension of your engineering department and will work directly with you to devise the right designs, integration, and execution strategy for your vehicles.

Mobile system integration for industrial machinery

Benefits of Vehicle Electrification

These days, it’s not just cars that are run on electricity. Commercial, medium, and heavy duty industrial vehicles are seeing more and more incentives to move into electrification.

While there is a strong argument to be made that the driving forces are mandates and emission standards, there is also a case to be made for the inherent efficiency of electric vehicles.

The energy to operate an industrial electric vehicle comes from an onboard battery, charged through shore power or engine-mounted generators. This does away with the need for a combustion engine as the electrical energy is converted into mechanical energy through the electric motor.

The benefits of full electric powered hydraulic machines are obvious to many manufacturers. They don’t require any fossil fuels or emit any CO2 while operating. Further, an electric drive is made up of far fewer parts (in particular, far fewer moving parts). This means breakdowns are less frequent and maintenance less time-consuming. Because the design is less complex, it is also smaller. This alone can be a strong selling point for limited space vehicles.

Onboard Generators

Idle Reduction Systems

Electric Power Take Off Systems

Electric Vehicle Prototyping

Custom System Designs

Full-System Optimization

Components for Every Part of your Electrification project.

Whether you need the right electric drive, battery pack, or power inverter, we have you covered. Our team has experience in energy mapping mobile machines in a range of applications. Paired with access to an industry-leading selection of manufacturers, we can implement the right components into your design so you have the power and range you need in the field while maintaining efficiency.

Industrial Vehicle Electrification 1

Industrial Vehicle Electrification 2

Component:
Electric Motor

Manufacturer:
ENGIRO / HYDAC

Description:
Permanent Magnet motors for maximum efficiency on your electric/hybrid machine. With design ranges from 5kW to 400kW of power, low and high voltage, air and liquid-cooled, we have a product that will fit your machine's needs.

Learn More →

Danfoss main company logo

Component:
Shhark Gear Pump

Manufacturer:
Danfoss

Description:
Ultra low-noise hydraulic gear pumps in varying flow and pressure ranges, you can experience a dramatic decrease in noise over a standard gear pump. Noise reduction is an important aspect of the features provided by an electric machine.

Learn More →

Danfoss main company logo

Component:
Hose Assemblies

Manufacturer:
Danfoss

Description:
Cross Company can develop and provide a complete Winner hose kit for producing your machine. These kits can help OEMs manage the flow of product through their production areas in a much more efficient manner.

Learn More →

Industrial Vehicle Electrification 3Component:
Displays

Manufacturer:
IFM

Description:
Cross Company can develop a custom HMI for your machine. On electric vehicles not only do we include battery information, but we typcially include troubleshooting pages that will allow for the easier servicing.

Learn More →

Industrial Vehicle Electrification 4Component:
Battery Pack

Manufacturer:
Inventus Power

Description:
Cross Company is using Inventus Power’s 48-volt PROTRXion lithium-ion battery solution for this off-highway application. The 3.2-kilowatt-hour battery pack is modular and can be scaled in parallel to increase power and runtime needs. The robust battery management system (BMS) provides critical communications to the system and has built-in safety protection.

Learn More →

Industrial Vehicle Electrification 5Component:
Battery Charger

Manufacturer:
Delta-Q

Description:
Cross Company integrates Delta-Q's onboard battery charging technology into a range of our mobile electrification projects. These products vary from nominal charging voltage to power output, we have a charger that will fit your application requirements.

Learn More →

Industrial Vehicle Electrification 6Component:
Motor Inverter

Manufacturer:
Inmotion

Description:
InMotion inverters are available in different voltage platforms, and current handling capabilities. Here at Cross Company, we have been implementing these motor controllers for a number of years utilizing different motor vendors and motor technologies.

Learn More →

Industrial Vehicle Electrification 7Component:
Power Distribution Unit

Manufacturer:
Cross Company

Description:
Cross Company has developed an in-house 48-volt power distribution unit to use as a standard offering on electrification projects. Incorporating contactors, fuses, and quick disconnect connectors, our PDU comes in a small package and simplifies wiring.

Learn More →

Industrial Vehicle Electrification 7Component:
Custom Manifold

Manufacturer:
Cross Company

Description:
Cross Company designs and manufactures custom hydraulic manifolds. Optimizing aspects of your hydraulic system design, custom manifolds can provide benefits such as lessening pressure drop and heat generation. For electric machines, this is critical to more efficient hydraulics, and in turn, reducing battery usage.

Learn More →

Components for Every Part of your Electrification project.

Whether you need the right electric drive, battery pack, or power inverter, we have you covered. Our team has experience in energy mapping mobile machines in a range of applications. Paired with access to an industry-leading selection of manufacturers, we can implement the right components into your design so you have the power and range you need in the field while maintaining efficiency.

Industrial Vehicle Electrification 2

Component:
Electric Motor

Manufacturer:
ENGIRO / HYDAC

Description:
Permanent Magnet motors for maximum efficiency on your electric/hybrid machine. With design ranges from 5kW to 400kW of power, low and high voltage, air and liquid-cooled, we have a product that will fit your machine’s needs.

Learn More →

Danfoss main company logo

Component:
Shhark Gear Pump

Manufacturer:
Danfoss

Description:
Ultra low-noise hydraulic gear pumps in varying flow and pressure ranges, you can experience a dramatic decrease in noise over a standard gear pump. Noise reduction is an important aspect of the features provided by an electric machine.

Learn More →

Danfoss main company logo

Component:
Hose Assemblies

Manufacturer:
Danfoss

Description:
Cross Company can develop and provide a complete Winner hose kit for producing your machine. These kits can help OEMs manage the flow of product through their production areas in a much more efficient manner.

Learn More →

Industrial Vehicle Electrification 3Component:
Displays

Manufacturer:
IFM

Description:
Cross Company can develop a custom HMI for your machine. On electric vehicles not only do we include battery information, but we typcially include troubleshooting pages that will allow for the easier servicing.

Learn More →

Industrial Vehicle Electrification 11Component:
Battery Pack

Manufacturer:
Inventus

Description:
Cross Company is using Inventus Power’s 48-volt PROTRXion lithium-ion battery solution for this off-highway application. The 3.2-kilowatt-hour battery pack is modular and can be scaled in parallel to increase power and runtime needs. The robust battery management system (BMS) provides critical communications to the system and has built-in safety protection.

Learn More →

Industrial Vehicle Electrification 5Component:
Battery Charger

Manufacturer:
Delta-Q

Description:
Cross Company integrates Delta-Q’s onboard battery charging technology into a range of our mobile electrification projects. These products vary from nominal charging voltage to power output, we have a charger that will fit your application requirements.

Learn More →

inmotion logo evComponent:
Battery Inverter

Manufacturer:
Inmotion

Description:
InMotion inverters are available in different voltage platforms, and current handling capabilities. Here at Cross Company, we have been implementing these motor controllers for a number of years utilizing different motor vendors and motor technologies.

Learn More →

Industrial Vehicle Electrification 13Component:
Power Distribution Unit

Manufacturer:
Cross Company

Description:
Cross Company has developed an in-house 48-volt power distribution unit to use as a standard offering on electrification projects. Incorporating contactors, fuses, and quick disconnect connectors, our PDU comes in a small package and simplifies wiring.

Learn More →

Industrial Vehicle Electrification 13Component:
Custom Manifold

Manufacturer:
Cross Company

Description:
Cross Company designs and manufactures custom hydraulic manifolds. Optimizing aspects of your hydraulic system design, custom manifolds can provide benefits such as lessening pressure drop and heat generation. For electric machines, this is critical to more efficient hydraulics, and in turn, reducing battery usage.

Learn More →

Practical Vehicle Electrification

Many are hesitant to electrify their fleets or shift to an EV-centric production model as they’re concerned electric vehicles won’t be able to perform as well (or as long) as the traditional ICE models. But when industrial vehicle electrification is done right, it can not only perform as expected, but often with greater efficiency.

In an internal combustion engine machine, the engine must be running at all times, even while idling. It also controls auxiliary functions of the machine, such as pumps, rotating parts, compressors, HVAC, lights, and many other functions. This wastes fuel and puts strain on the engine, shortening its overall lifespan and increasing the need for maintenance.

With off-road electric vehicles, these are all functions that can be performed by an electric motor with greater efficiency, less strain, and lower maintenance costs than a machine with an internal combustion engine.

It all comes down to understanding the needs of your individual machine. At Cross, we take the time to understand your unique needs, from manufacturing to end-user. That way, we can design and prototype a practical vehicle electrification solution.

The Right Electrification Partner

As a mobile machine OEM, there are many reasons you might consider implementing electrification solutions over traditional ICE systems. It could be simply to satisfy a market demand such as low or no emission requirements, or to take advantage of green power credit initiatives. Or it could be about the increased efficiency over the vehicle’s lifespan. Of even just to be able to cut diesel fuel out of the budget.

Whatever the reason, Cross is your work vehicle electrification partner. We’ll work with you to design the right system to get the job done.

Construction

Recycling

Utility Vehicles and Work Trucks

The Industrial Vehicle Electrification Company You Need

At Cross, we offer much more than just full solutions for mobile machinery and vehicles. We can also provide the services our OEM and other equipment manufacturer partners need to succeed. Take a look at our featured services for mobile systems.