Batteries and Battery Management Systems
Battery Solutions for Mobile Machinery
As electrification in manufacturing becomes more and more common, the need for EV batteries has only become more important. Although electric cars may come to mind first when considering EV batteries, there is also a rapidly rising demand for batteries for mobile industrial machinery. Lithium-ion batteries have an extremely high energy density which allows them to store a large amount of energy in a small package. This has significant advantages over the low energy density of a traditional Lead-Acid battery.
In today’s rapidly changing industrial marketplace, greater demand is being put on mobile work machinery. These off-road machines need to be able to perform efficiently while meeting noise restrictions, emission requirements, idling standards, and many other demands. Utilizing Li-ion batteries can solve many issues while maintaining (or in some cases, improving) existing machine performance.
Further, we’ll implement battery management systems for your electric machinery. That way, you can always know your battery health status and effectively monitor levels of charge and wear.
At Cross Company, we work directly with you to determine how electrification for your heavy equipment can benefit your operations or increase your production scalability. As electrified machinery becomes more prevalent in manufacturing, it’s important to keep up. We’ll make sure your operation doesn’t get left behind.
Increase Your Equipment Efficiency
As the industrial marketplace becomes more competitive, it’s critical for OEMs and other equipment manufacturers to stay ahead of the curve. One of the ways many are doing this is switching away from lead-acid battery reliance.
Utilizing lithium batteries for mobile machinery is a reliable way to improve machine performance, battery productivity, and overall quality. Lithium machine batteries require significantly less maintenance, don’t require added water, and don’t necessitate cleaning residue from cables, battery tops, and other equipment.
Don’t let your production fall behind your competitors. Start the process of upgrading to a reliable and durable battery solution today.
Batteries With Intelligent Management
Our on-board battery management system reports data utilizing CAN communication. They are able to provide overcharge and over discharge protection, real-time monitoring of voltage and temperature of every cell, state of charge, voltage and current monitoring of the entire module. Our packs give you the information you need to safely and efficiently control your battery pack.
In addition, our BMS allows for flexible settings. This could be critical to increasing your battery life in high current or high temperature applications. It also means they can be made to suit your unique needs and industry requirements. The additional feedback and control provided by a BMS also allows for customization of your charging and discharging requirements.
Lithium batteries for mobile machinery provide many benefits, including
Increased Life
Replace packs less often
Increased Energy Density
Packs are smaller and lighter
Increased Capacity
Less charging, more working
Increased Savings
Cut gas costs
Increased Efficiency
Faster charging times
Increased Performance
Less Maintenance downtime
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.
Industries Served
Construction
Recycling
Utility Vehicles and Work Trucks
Lithium-Ion Battery Solutions
There are many reasons why an OEM would choose to utilize a lithium iron phosphate battery for a mobile machine. From the difficulty of damaging the battery itself to resistance to over or under-charge damage, more manufacturers are utilizing this battery technology in their manufacturing process and machines than ever before.
A top concern for many vehicle operators (and, in turn, the manufacturers) is the battery charge. How long will a single charge last? And how long will it be until the battery is back to fully charged after a full depletion? These are two important considerations. If your battery runs out mid-job, are you just left high-and-dry?
If that’s a concern of yours, we would suggest lithium iron phosphate batteries. When compared to a standard lead acid battery, they have double the run time, weigh half as much, and can last up to 10x longer. That’s not just a good battery, it’s a full solution.
On-board Battery Management System (BMS)
Deutsch connector used for CAN communications
Lightweight design and compact form factor
Different voltage and watt hour configurations
Integrated pre-charge circuit design and cell heaters for charging in low temperatures
Cross Customized 48 Volt Battery Packages
Safety is always a top concern when manufacturing a mobile work vehicle. One method of improving vehicle safety is through battery management systems (BMS). When working with battery-powered industrial equipment, it is crucial to prevent voltage, current, or temperature from exceeding defined limits during charging or discharging. This is where a BMS shines. Always know the status of your batteries with a reliable BMS.
Utilizing a BMS does more than just increase overall vehicle safety, though. They also effectively safeguard performance, promote longer battery lifespan, and maintain machine quality over time.
At Cross Company Mobile Systems Integration group, we can develop different battery packages based on your application. If your machine requires higher power or has size restrictions imposed from outside, custom battery packs can be developed to get you the power you need. We’ve been able to accomplish ideal battery solutions through gearboxes, custom design, and expert engineering. And we can do the same thing for your application, too.
Frequently Asked Questions
If you are using the battery every day or for extended periods of time, an LiFePO4 battery is by far the most efficient option. A lithium iron phosphate battery can’t be damaged by over or under-charging and can run for more than double the amount of time of a lead-acid battery in similar conditions.
While, strictly speaking, a lithium battery doesn’t require a battery management system to operate, we wouldn’t recommend going without one. In order to prevent unexpected battery failure and help reduce the number of potentially hazardous situations, we always recommend some sort of monitoring system for the battery. That system is the Battery Management System.
It is a fact that over the years, lithium batteries have become more efficient and better suited for heavy machinery. Increases in the amount of energy stored in batteries has been steadily increasing by a factor of 5% each year. That means current batteries can store almost double now what they would have been able to store less than a decade ago.
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Why Cross Machine Batteries?
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!
