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.
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.
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.
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.
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.
Component:
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.
Component:
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.
Component:
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.
Component:
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.
Component:
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.
Component:
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.
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.
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.
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.
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.
Component:
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.
Component:
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.
Component:
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.
Component:
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.
Component:
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.
Component:
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.
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.
Frequently Asked Questions
There are many reasons to make the switch to electrification. Some are external, such as emission reduction mandates or noise concerns while operating. Others are internal, such as seeing a developing trend in the market and wanting to maintain a competitive edge over other manufacturers. And some are purely based on efficiency or fuel costs. Whatever the reason, it’s impossible to deny that the trend is towards more electrification and less fossil fuels.
Few industries don’t stand to benefit from implementing electrification. Vehicle electrification for construction, vehicle electrification for municipal operations, and electrification for utility vehicles are just a few examples of instances where making the switch to electric industrial machines can be beneficial in the long run.
To get started, we recommend talking with one of our mobile work vehicle electrification experts. Then we’ll take the time to learn the needs of your unique machine, production process, and end users. With all those factors in mind, we’ll work with you to devise a prototype and plan for implementation.
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Why Cross Vehicle Optimization?
If you’re looking to increase your work vehicle’s lifespan, efficiency, and compliance, Cross vehicle electrification is the best solution. We’ll work with you every step of the way, from concept to completion. That way you know exactly what you’re getting and how it will improve your mobile vehicle.
From electric motors to space allocation, we can optimize your vehicle for performance, lifespan, and durability.
Contact a Cross Mobile System Integration expert today to discuss the optimization of your mobile work vehicle.