The presentation discusses challenges in industrial vehicles E/E development as the vehicles of the future will be more and more electrified, connected and autonomous. As traditional industrial vehicles typically include low-efficiency hydraulic systems and are rather manually operated, electrification and autonomous features offer huge opportunities for improving safety, efficiency and energy consumption, but require rethinking of the electrical and electronic system architecture. The presentation will cover solutions and design considerations for various system components such as electric actuators, sensors, high-calculation computers and electromobility system components. Seamless integration solutions with these main systems components and vehicle control systems will be also discussed.

What the audience will learn

• Design considerations for development arising from autonomous driving features and electrification
• How hydraulics can be replaced with more efficient solutions
• How simulation-based systems engineering should be used in development
• Benefits and challenges of next-generation control systems and software architectures in industrial vehicles
• How industrial vehicle attachment design will change in the near future and how to choose the most effective practices for implementing futureproof vehicles

Aradex and Henkelhausen's joint presentation explains the benefits of utilizing standard components and pre-validated software modules to electrify off-highway machines by creating a hybrid powertrain that combines electrification and combustion engine technologies. The recently completed pilot project demonstrated that combining the expertise and existing products of two companies can significantly reduce the development effort and lead times per use case.

What the audience will learn

• How to accelerate and reduce the initial investment of an electrification project by presenting the relevant development steps
• How to work together to reduce the complexity of electrification projects
• The benefits of a hybrid powertrain as an efficient redesign of an existing machine
• Trade-off decision making: use case requirements versus technical optimum versus time-to-market
• Opportunities for integrating additional functionality and comfort features through additional powertrain control automation

The presentation covers the operation-specific solutions that Hibra Design offers to its clients to decarbonize off-highway industrial vehicles. Hibra Design is an automotive engineering development company based in Ireland that develops sustainable and bespoke vehicle solutions including clean technology powertrain systems allowing fossil-fuel-powered vehicles to be re-engineered with battery-electric or hydrogen fuel cell systems. This allows industrial companies to significantly reduce operational costs and meet environmental and corporate social responsibilities. Alongside this, the vehicle solutions produce healthier working environments and increase production efficiency. The presentation will show how Hibra Design develops battery-electric solutions designed simultaneously for the vehicle and specific operational duty cycles. It will showcase solutions that can be applied to a broad range of industries from ground-handling vehicles to vehicles helping to repair peat and boglands.

What the audience will learn

• How heavy industrial vehicles can be reengineered for battery-electric solutions
• How vehicles are engineered for operation-specific requirements
• How Hibra Design solutions can be applied to a wide range of industrial vehicles
• How Hibra Design reduces clients' operational costs including energy costs, maintenance costs and legislative costs

Electric off-highway machines are feasible, but how can we make them more desirable and speed up adoption? In his presentation, Alastair Hayfield will outline innovations and technologies that will help boost the adoption of electric machines across a variety of sectors and applications. He will take the audience through examples from within and outside of the off-highway market and show how simple ideas can revolutionize the market appeal and acceptance of electric machines.

What the audience will learn

• The size and potential of the electric off-highway machine market
• Innovations and technologies that will speed up adoption of electric machinery
• Alternative business models and ways to address the concerns of operators

Designing electric fans for ZEVs requires careful consideration of voltage selection, noise reduction techniques, configuration trade-offs and specific factors unique to zero-emission vehicles. By addressing these considerations, manufacturers can develop efficient and reliable e-fan solutions that contribute to the performance and sustainability of ZEVs.

What the audience will learn

• Design considerations associated with an e-fan for ICE versus ZEV vehicles
• Why does voltage matter when speccing an e-fan?
• Reducing noise will be a critical aspect of the e-fan design

This presentation deals with the typical applications of mobile electric auxiliary drives used in construction machinery, harvesting machines or emergency vehicles in the public and military sectors. By running these drives at the optimum operating point, it is possible to maximize efficiency, optimize cost and increase operational safety.

What the audience will learn

• Typical applications for electric auxiliary drives
• Types of electric auxiliary drives
• Advantages and dissadvantages of different electric auxiliary drives

Toshiba’s vision is to contribute to the realization of a sustainable society by supporting the global trend of decarbonization via electrification. One key solution to do this is the Toshiba rechargeable lithium-ion battery SCiB with a lithium titanium oxide (LTO) anode. One of the six key advantages over conventional carbon-based batteries is the extreme cycle lifetime. Depending on the load profile, the lifetime of SCiB can be 15 times longer. This reduces waste caused by multiple battery replacements during the lifetime of the end product and minimizes the total cost of ownership (TCO), which is one of the key metrics for industrial heavy-duty applications.

What the audience will learn

• How the total cost of ownership (TCO) of their applications can be minimized
• The difference between carbon-based Li-ion battery cells and battery cells with lithium titanium oxide (LTO) anode
• The benefits of lithium titanium oxide (LTO) battery cells

The presentation will define the challenges in the electrification of off-highway machinery – amongst them operating time, high energy requirement, complex vehicle installation spaces. We will show which solutions Webasto can offer, to overcome these obstacles. By using customer examples, we would like to illustrate the latest Webasto solutions for electrification purposes.

What the audience will learn

• Electrification of off-highway machinery: what challenges need to be considered
• How these challenges can be overcome
• Customer cases: best practices

This presentation navigates the electrification landscape, unraveling megatrends driving the shift. We dissect the total cost of ownership for machines, emphasizing the role of efficiency in electrification. Delve into Danfoss's approach, ranging from engine swaps to system-wide optimizations, uncovering strategies for hydraulic efficiency improvement. Explore our product offerings empowering OEMs in their electrification journeys. A spotlight on applications, using an electric wheel loader as a case study, showcases current architectures and avenues for improvement based on duty-cycle data. Concluding with a business outlook and expected electric adoption rates, this presentation offers a comprehensive guide to navigating the electrified future.

What the audience will learn

• Megatrends driving the shift to electrification and hydraulic efficiency improvements
• Electric wheel-loader case study showcasing current architectures for higher efficiency
• Guide to navigating the electrification of the mobile off-highway industry
• The wide product portfolio of Danfoss Power Solutions

This presentation will examine the trade-offs between alternative fuels for NRMM, including battery electric, fuel cell electric, hydrogen-ICE, renewable diesel and e-fuels. A summary of KGP's current forecast outlook for fuel use by market vertical for construction, AG and material handling will be included. Challenges for electrification, including charging, battery availability and cost, will be addressed, with views on future legislative and financial support required to meet net zero targets.

What the audience will learn

• NRMM energy and fuel requirements
• Trade-offs between electric and other alternative fuels
• Challenges to market adoption
• Future legislative and incentive recommendations

The mobile equipment industry has entered a phase of major redesign to meet the growing demand for environmentally sustainable operations. Electric technology has matured into viable solutions for mobile use, coinciding with a rapid advancement of data technologies. In combination with hydraulics as a proven and essential system element, the productivity, functionality and resource efficiency of working machines can be enhanced fundamentally. The presentation highlights the potential of novel system architectures, looks at realized as well as upcoming solutions, discusses remaining challenges for equipment OEMs and system suppliers and provides guidance for decision processes toward advanced machines.

What the audience will learn

• Look at pros and cons from the perspective of a neutral market expert
• See concepts and alternatives for future-oriented system architectures
• Evaluate the technology readiness of necessary and optional system elements
• Understand technical and commercial challenges for system and component designers
• Receive guidance for system selection, design and strategy

Mobility is changing and more and more battery-powered vehicles are in use. Be it in passenger cars or in the NRMM sector, the big question is the condition of the battery, be it the health, state of charge, or the user profile – which includes charging cycles – as well as the battery load cycles. Vehicle manufacturers use the net and gross capacity of the battery, which makes it even more difficult to determine the battery condition. Although the vehicle manufacturer provides information about the battery condition, this should be viewed with caution. This presentation gives an independent battery test system that analyses and evaluates the condition of the battery in just a few minutes, independently of the manufacturer, and creates a use case profile. This allows the historical use of the traction battery to be visualized with load scenarios, as well as the battery capacity still available. The battery test system uses AI methods to determine and analyze the battery condition. This enables statements to be made about the further life cycle and possible second-life utilization. The battery test system is part of a subsidized three-year research project.

What the audience will learn

• The independent evaluation and identification of traction battery level parameters
• How to independently determine the state of health of a traction battery
• Why and what is the background of the evaluation of the battery parameters
• What does this mean for the second life of the battery
• Is there a correlation between the user profile and the battery life status?

In this presentation we focus on applications of small auxiliary converters. We examine how these devices contribute to sustainability, while looking ahead to future developments. One application is the recuperation axle, where our dual inverter technology efficiently captures energy during braking to charge a battery and reduce the CO2 footprint of cooling trucks. We show how the dual inverter can be used as an active front-end and DC-DC converter. This technology can power auxiliary systems such as air-conditioning and hydraulic pumps in various applications. Through examples, we provide insights into a more efficient and sustainable future for industrial vehicles.

What the audience will learn

• Explore the practical applications of small auxiliary inverters, emphasizing their role in enhancing industrial vehicle efficiency
• Witness the application of our dual inverter technology in the recuperation axle, where two generators seamlessly charge a battery
• See additional applications for dual inverters for grid-connected applications and battery applications

When it comes to the electrification of the drivetrain, commercial vehicles in particular impose special requirements on the energy storage system and the associated range. Against this background, the installation space requirements, efficiency and performance of the electric motor play an even more important role. With the increasing transformation from conventional to electric drives, numerous innovations in the field of electric motors can be observed. However, due to the different requirements profile compared to passenger cars, not all innovations can be transferred unconditionally to the commercial vehicle sector and their suitability must be examined against the background of the effects, for example, on the installation space requirement, the efficiency of the drivetrain or the performance capacity.

What the audience will learn

• How can different commercial vehicles be categorised in terms of their performance requirements for the electric drivetrain?
• To what extent do the powertrain design requirements for commercial vehicles and passenger cars differ?
• Which current innovations in the field of electric motors can be identified and how suitable are these for commercial vehicle powertrains?

The presentation will provide insights into the electrification of the commercial vehicle industry in various application scenarios. It will also highlight the extent to which electrification goes hand in hand with transformation and how this can be mastered in times of crisis, especially in a small and medium Tier 1 enterprise. Specific application examples from the SME sector as well as do's and don'ts of transformation in the electrification of vehicles will be presented.

What the audience will learn

• Electrification in the commercial vehicle sector is different in comparison to the personal car sector
• How to change a SME enterprise toward electrification in times of crisis
• Do's and don’ts that should be addressed in such a transformation process

Explore the transformative impact of styling on electrical vehicles (EVs), beyond aesthetics. This presentation delves into styling's pivotal role in shaping EV engineering and design, emphasizing its influence on market presence, brand identity and consumer connection. Investigate the synergy between form and function, as aesthetics contribute to user experience and product usability. Case studies illustrate how strategic styling choices lead to environmentally sustainable solutions, optimizing EV performance. Uncover economic implications, as styling decisions affect manufacturing costs, market competitiveness and overall EV success. Discover the dynamic interplay between engineering precision and aesthetic finesse, unlocking styling's full potential in the EV realm.

What the audience will learn

• The impact of styling on environmental sustainability
• The impact of styling on production costs and overall profitability
• The impact of styling on ergonomic aspects of a product
• The relationship between styling and mechanical engineering

CVEP and MTConnectivity present innovative new technologies. Press-Fit technology developed by MTConnectivity offers significant advantages compared with conventional PCBs, for difficult operating conditions and e-mobility – explained with application examples. Based on this technology, CVEP presents a new, sustainable concept for central electrics. The modular system covers base boards and individual components, e.g. the new generation of CVEP universal relays U2 series. Users receive an eco-friendly overall concept with high performance potential, prepared for the requirements of e-mobility and commercial vehicle automation. This concept is completed by a patented 48V power switch for e-drive systems. The ergonomic CVEP Hexswitch CAN keypad provides the interface.

What the audience will learn

• Advantages of Press-Fit technology
• Sustainable new central electric concepts for commercial vehicles
• Efficient solutions for high-performance electrical systems and e-mobility

The presentation is based on the experience gained from a large number of customer projects and series vehicles of an electrification pioneer and provides a well-founded overview of the possible applications of forklift components in NRMM machines. The technical and legal requirements (e.g. for telescopic handlers and wheel loaders) will be discussed and the resulting advantages for NRMM electrification projects with forklift components will be demonstrated. We will provide an overview of our project experience at the component level and also present the integration system at the machine level, which has proved to be the most adaptable and successful in NRMM electrification projects.

What the audience will learn

• NRMM project learnings of an electrification pioneer
• Overview of the possible applications of forklift components in NRMM (e.g. telehandlers and wheel loaders)
• Main benefits of using forklift components in NRMM electrification projects

Can the heavy material handling industry go fully electric in 2024? Yes, there have been products and solutions available to meet these demands for some years. The presentation will provide a condensed overview, understanding and lessons including the latest offerings and the technologies behind them. It will cover products and solutions based on forklifts, reachstackers, container handlers, straddle carriers and terminal tractors.

What the audience will learn

• Can the heavy material handling industry go fully electric in 2024?
• Current electrified offerings available and the technologies behind them
• Electrified lessons

The pathway for non-road mobile machines toward fossil fuel-free energy solutions is still at the beginning of its story. The mobile work machine sector is one of the largest energy consumers. From construction to port operations, logistics and agriculture, fossil fuel-free energy solutions are becoming more achievable for industries that use mobile work machinery. Due to the different operating environments, the green transition presents different opportunities and challenges for different industries, but one thing is true for all: new, efficient and fossil fuel-free energy solutions can potentially transform work machines and entire sectors.

What the audience will learn

• New value and benefits from electrified mobile machines and worksites
• Tools and methods to calculate and evaluate the potential of electrification of NRMM for different applications
• Different conditions to be taken into account in the evaluation of the potential of solutions

The SIX mobile machines cluster has outlined an innovation roadmap for future mobile machine vision, which consists of seven thematic areas. It builds on an up-to-date picture of the machine of the future, with the picture being drawn by industry. Against this picture research, the players have defined what kind of research is required and what kind of expertise is needed. In between, there is a clear implementable continuum of development activities that committed players from industry, research and education are implementing in real life. The roadmap shows where the mobile machines industry is headed.

What the audience will learn

• Practical future vision of the future mobile machine
• Inspiration for creating an actionable, up-to-date future roadmap
• Platform for mission-driven collaboration guided by the joint roadmap

Fault prevention and real-time knowledge of batteries’ state of health is possible with Flash Data Center: the intelligent automatic remote control system by Flash Battery which, through artificial intelligence and machine learning algorithms, constantly learns, stores and processes the operating data of each battery system installed (200 million logs), allowing real optimization of machine use. The software, integrated in a virtual environment with containerized architecture, recreates a digital twin of each battery, analyzes its SOH 24/7 and enables OEMs to perform self-diagnostics, predictive maintenance and advanced big data analysis of their battery systems. This improves machine performance and boosts productivity.

What the audience will learn

• The automatic, 24/7, remote monitoring of the SOH of a lithium battery by artificial intelligence enables self-diagnostics and predictive maintenance
• Predictive analysis allows getting information on the effective use of an application and estimating the battery life on the vehicle
• Implementing remote control at the prototype stage allows correct sizing of the battery inside the vehicle (size, energy, performance)
• Machine learning data control enables advanced planning of extraordinary maintenance work and autonomous management of systems’ end of life
• Flash Data Center predicts future battery behavior to study new generations of smarter lithium batteries and high-performing vehicles

Axial flux motor topology offers a compelling advantage in terms of its compact form factor and high torque and power density. Existing offerings of this technology remain restricted to niche applications but it holds tremendous potential if design innovations to make it a volume-friendly solution are implemented. The presentation will explore the market and technology landscape of axial flux motors and how design and production innovations can enable their application in high-volume mainstream applications.

What the audience will learn

• Axial flux motor global market
• Technology enabling the axial flux motor topology
• Benefits – commercial and technical – of the axial flux arrangement
• Design and development of the high-volume production-friendly axial flux motor

Through a few examples of equipment for industries like material handling and access, we will review the benefit of electromechanical actuators versus hydraulic systems used for the lift functions on BEVs but also valid for vehicles with IEC and PTO generators.

What the audience will learn

• The regenerative braking of lift systems makes a big difference in the overall efficiency of the machine
• The new EMA-100 is more compact than the former Ewellix actuator and is cheaper for the same performance in lifting
• The upfront cost of electrification of a lift will be minimized by the smaller battery pack and the cheaper actuator
• Work with a machine equipped with EMA is smoother and allows more productivity and facilitates automation and robotics
• EMAs allow mobile machinery to work in clean rooms

Almost every sector is pressured with emission reduction goals, up to complete elimination in inner-city applications. Vehicle builders face many challenges in this transition, among which is the choice of the right electric drivetrain. But once the drivetrain concept and size are chosen, the implementation marathon begins on tight budgets. This presentation will give an introduction to the Engiro and Hydac experience, setting up electric drivetrains for mobile machinery in the power range from 10 to 400kW and 48 to 800V. An electrification kit approach will be presented, which can reduce time-to-market tremendously for vehicle manufacturers.

What the audience will learn

• Vehicle requirements engineering
• System design of electric drivetrains
• Electrification kits to speed up time-to-market

The presentation will discuss what is being requested by today’s commercial vehicle OEMs and systems suppliers and what is being done to address their requirements and the challenges therein.

What the audience will learn

• OEM industrial/commercial vehicle needs are different from those of e-mobility vehicles
• Evolving trends around e-mobility vehicles that OEMs and system suppliers should be aware of
• Advised considerations when designing e-mobility vehicles

TS-RFPM (Trapezoidal Stator Radial Flux Permanent Magnet) motor technology offers several advantages for OEMs looking to embrace e-solutions for industrial electric vehicles. The first is size and weight reduction – it enables the use of smaller and lighter motors than traditional motors, leading to overall vehicle weight reduction which is crucial for industrial vehicles aiming to maximize payload capacity and efficiency. It also offers flexibility in motor design – the ability to provide different voltage, power and speed options within the same motor design offers flexibility for OEMs in choosing the right motor for their vehicle platforms.

What the audience will learn

• What advantages does TS-RFPM technology offer for OEMs looking to embrace e-solutions?
• How does TS-RFPM technology enable the size and weight reduction of e-motors?
• What flexibility does RFPM technology provide for OEMs?

In response to the demand for carbon-neutral powertrain solutions in construction machinery, AVL conducted a case study on adapting battery-electric and fuel-cell-electric systems for excavators. The study focused on use profiles of existing machines, drivetrain simulations and optimizing operational strategies without compromising performance. Balancing fuel cell and battery performance, considering component aging and identifying off-the-shelf components were crucial steps. Integration of the components into the target vehicle involved configuring the high-voltage onboard network and designing the thermal system. This initiative addresses emission-reduction requirements even though specific legal regulations for the construction machinery sector are yet to be implemented.

What the audience will learn

• Setup of a CO2-free commercial vehicle powertrain using a fuel cell in a conventional powertrain topology
• Impact of fuel cell and battery size on the operating strategy
• Compliance with the specifics of currently available fuel cell solutions on the market

Our motto has always been, "We help our customers to overcome the challenges of electrification". One cost- and time-beneficial way is to use standard components that are already in production and available for attractive pricing. Additional USPs are that these components are already certified and road proven. Lion has integrated such battery packs into various applications and will report on the hurdles and challenges. Never stop. Always accept the next challenge to stay successful in your business. Lion grew by this to €56m of revenue and is aiming for €100m in a few years.

What the audience will learn

• Integration of existing solutions
• Proven technology – cost sharing
• Ramp-up and different requirements in different applications
• Price war with Chinese companies
• High quality and service can make a difference

This presentation introduces the pivotal role of relays and contactors in electric IVT. It explains the challenges posed by increasing battery voltages and currents and the need for ruggedness and reliability in such vehicles. It also discusses the design features and innovative solutions to address those challenges to meet customer demands for reliable higher-voltage and higher-current switching, in smaller and lighter packaging.

What the audience will learn

• Understanding HVDC startup sequences. Process of how high-voltage systems are interconnected, managing current flow and safety during startup
• Highlighting the significance of the correct selection of relays and contactors to ensure safe operation and protect equipment in high-voltage systems
• Understanding how current flow affects arc handling and the need for polarized or non-polarized contactors based on specific requirements
• Understanding the importance of contact material, its quality and the design of contact rivets in mitigating potential failures
• Demonstrating how design modifications can enhance safety by preventing potential hazards when using high-voltage systems