From Diesel to Electric: Transforming Heavy Machinery 

A leading construction and mining equipment original equipment manufacturer (OEM) headquartered in the U.S. aimed to develop a high-performance, electric-powered machine that could match or exceed the capabilities of its diesel counterparts. The goal was to support sustainability initiatives and prepare for a future of electrified heavy machinery.

Challenges

This application had many technical challenges including:

• Transitioning from diesel to electric powertrains required new expertise in high-voltage powertrain drive systems, battery management, and software integration
• Complexity of system design & architecture
• Testing and commissioning of the electric machine and ensuring operator familiarity and safety with new systems.
• Addressing space restrictions because the chassis was not designed for electrification
• Maintaining performance, reliability, and cost-effectiveness in a new electric platform
• Design to a level that is satisfactory for series production readiness

Solution

An expert electric component manufacturer was tapped as the primary developer and supplier of the complete electrification system for the diesel compact wheel loader. This included full systems integration of several key components including axial flux motors, power inverters, battery system and battery management system, pumps, fans, low- and high-voltage power distribution unit, power cabling/harnesses, DCDC, and software. Key products and deliverables included:

• Battery pack and charging systems that enabled reliable runtime and efficient energy regeneration
• Traction motor and inverters to deliver intuitive and responsive drivetrain control, which was praised by operators
• Thermal CFD and battery deflection analysis for system durability and performance under demanding conditions
• Duty cycle/application builder tool that allowed for precise simulation and prediction of battery life and machine performance
• Software integration for features like auto idle, hill hold, and intuitive touchscreen controls
• Assembly/testing of two prototype development (PD) compact wheel loaders followed by two pilot “series production representative” demonstration machines (at high-voltage-approved development/manufacturing facilities)

Operators described the compact wheel loaders with these technologies: “As good as the diesel, and better in some places.”

Impact

The project demonstrated strong operational performance with more than 500 machine hours, validating the electric platform’s reliability and effectiveness. Operators reported that the machine performed on par with, or even better than, its diesel counterpart, particularly praising its responsiveness and intuitive controls.

A comprehensive, high-voltage training program ensured that 86 team members across multiple sites were equipped to safely operate and maintain the new systems. Additionally, the project provided valuable insights into the evolving electric supply chain, highlighting both opportunities and challenges in sourcing components for low-volume production. These learnings are now shaping the OEM’s roadmap for scalable, cost-effective electrification of future equipment.