“We are fuel agnostic” is something that you can expect to hear from Diesel Progress staffers at trade shows or in meetings, especially when one of our business cards or an e-mail message lands in the hands of someone developing lithium-ion battery packs.
The industry has evolved since this magazine was founded in 1935, and so too has our editorial content and the way in which we connect with readers and advertisers. When it comes to the fuel source that makes all of this equipment function, we like it all.
Decision-makers who read Diesel Progress still buy a lot of engines – biodiesel, diesel, gasoline, methane and natural gas – and will continue to do so for the foreseeable future. However, the majority are also looking for a path to, and through, the world of electrification. With that reality in mind, the June issue of Diesel Progress carried the 42nd Engine Yearbook.
Folks in the dreamer, engineering, investor and marketing communities all see an opportunity in the battery electric vehicle and the hydrogen fuel cell electric machine, which makes for a dynamic landscape. The amount of news that this segment of the market generates is enough to keep one up at night.
There is a plethora of suppliers, from start-ups to established manufacturers – some were not even around for the 2020 edition of the New Power Progress Yearbook. And each claim that they are ready to assist in the development of an electric machine that is reliable, robust, safe and saleable.
6SYNCT CONSULTING INC.
Consultants focused on electrification in off-highway machinery.
Midland, Ontario, Canada
Web: www.6synct.com
News for 6Synct Consulting
The company selects the best solutions for each customer, boasts clients throughout North and South America and across the world. 6Synct claims that it uses an agile approach and does not supply one specific system to OEMs or end-users.
Past and present projects include:
ALLISON TRANSMISSION
Hybrid transmissions and electric axles for medium- and heavy-duty vehicles.
Indianapolis, Indianapolis, USA
Web: www.allisontransmission.com
The eGen Power electric axle from Allison Transmission
News for Allison Transmission
Originally designed and developed for buses, Allison stated that its eGen Flex avoids the inconvenience of having a limited range by deploying electric propulsion selectively and tops-up batteries through regenerative braking.
Their eGen Flex is expected to go into production in January 2022, replacing Allison’s H40/50 EP electric hybrid system. It builds on the H40/50 EP electric hybrid propulsion system to provide engine-off electric hybrid operation. Lithium-titanate (LTO) battery technology enables electric propulsion for up to 10 miles.
Allison’s eGen Power is a new series of fully integrated electric axles designed to fit between the wheels of trucks and buses and replace the vehicle’s traditional powertrain system. This bolt-in solution has fully integrated electric motors, a multi-speed gearbox, oil cooler and pump. The system is compatible with full battery electric vehicles, fuel cell electric vehicles and range extending hybrid applications.
The company said that its new eGen Flex electric hybrid propulsion solution, will be put into revenue service at New York City Transit (NYCT). GILLIG will offer the eGen Flex electric hybrid propulsion system on its buses.
Rohan Barua, vice president of sales for North America at Allison Transmission, explained, “GILLIG and Allison have established a joint partnership dedicated to optimized integration and a mutual commitment to innovation.
“We are excited to continue our history of innovation with Gillig through the launch of the eGen Flex propulsion system. The diesel engine can serve as a range extender, when needed for longer routes or route flexibility due to unplanned congestion or construction on routes.
“Through this solution Gillig and Allison can offer customers full EV capability while maintaining a diesel engine for added flexibility, effectively serving as a bridge solution to EV.”
Gillig stated that it has received its first order for eGen Flex electric hybrid-equipped buses from IndyGo, the Indianapolis Transportation Corporation.
Allison Transmission announced in April 2021 a strategic Memorandum of Understanding (MOU) with Emergency One (UK) Ltd to integrate the eGen Power 100D electric axle into fire rescue and emergency vehicles.
The electric axle integrates two high-speed electric motors and a multi-speed transmission, eliminating the need for additional driveshafts and support structures. It provides continuous power of 536 hp and peak output power of 738 hp. The company revealed that the eGen Power 100D is the first in a lineup of electric axles.
BAE SYSTEMS
Low and zero-emission electric drive propulsion systems for battery-electric, hydrogen fuel cell and electric-hybrid solutions.
Endicott, Broome County, New York, USA
Web: www.gettozero.com
BAE Systems has introduced its next-generation full battery electric power and propulsion system for transit buses
News for BAE Systems
Some 15 public buses in Vancouver, British Columbia, Canada, will be fitted with BAE Systems’ all-electric propulsion system based on electric motors, controls and batteries.
The company said in March 2021 that the fleet is the first in North America to use its next-generation Series-EV all-electric propulsion system, which uses fewer, lighter and more compact components. BAE Systems claimed that the light weight, reduced number of connections and use of advanced materials make it easy to install and efficient, which enables the buses to travel longer distances on a single charge.
Series-EV builds on more than 25 years of innovation and proven technology that powers buses all across the globe. The company’s all-electric systems are on buses in service throughout Europe.
BAE Systems announced that it was collaborating with Plug Power, a supplier of hydrogen engines and fueling systems, to offer hydrogen-based electric propulsion systems for transit bus fleets. The companies will collaborate to offer transit operators in North America an all-inclusive, scalable system to reach zero emissions, providing required site, service and vehicle solutions.
BAE Systems will integrate Plug Power’s fuel cell engines into its electric drive systems to power the bus. The strategic partnership leverages the combined knowledge and experience in electrification of each company.
BALLARD POWER SYSTEMS
PEM (proton exchange membrane) fuel cell systems for buses, commercial trucks, trains, marine vessels, passenger vehicles, forklift trucks and UAVs.
Vancouver, British Columbia, Canada
Web: www.ballard.com
Ballard’s 30kW FCveloCity-MD fuel cell power module was developed for use in heavy-duty motive applications
News for Ballard Power Systems
Ballard Power Systems announced in June 2021 that it received an additional purchase order from New Flyer for 20 fuel cell modules to power Xcelsior model fuel cell electric buses for deployment with Alameda-Contra Costa Transit District (AC Transit) in Oakland, California.
Deployment of the New Flyer buses will bring the total number of Ballard-powered buses operated by AC Transit to 31.
Ballard Power Systems and Linamar Corporation formed a strategic alliance in May 2021 for the co-development and sale of fuel cell powertrains and components for Class 1 and 2 vehicles, weighing up to five tons, initially in North America and Europe.
In the initial phase a fuel cell powertrain will be developed, with Ballard providing the fuel cell subsystem and Linamar providing both the rolling chassis and final assembly.
Following successful testing, Ballard and Linamar may contemplate the formation of a joint venture to sell and support powertrains with fuel cell systems and an interchangeable rolling chassis for use in a range of light-duty vehicles, including commercial vans.
BONFIGLIOLI USA
Electric wheel, travel, track and drum drives plus complete electric powertrains for forklifts, access and aerial platforms, agricultural and forestry equipment, airport vehicles, concrete mixers, construction equipment, light road vehicles and material handling machines.
Hebron, Kentucky, USA
Web: www.bonfiglioli.com
News for Bonfiglioli USA
The company, which boasts more than 40 years of experience in electromobility, has developed a range of electric drive technology. Bonfiglioli USA recently electrified two new products for compact track loaders, medium excavators and large boom aerial work platforms.
The 606W3E series wheel drive was developed for medium to large boom lifts (80ft to 210ft). The 705C2E and 709C2E track drives have been engineered to withstand harsh operating environments faced by medium to large excavators and compact track loaders.
All solutions incorporate either ac induction or internal permanent magnet electric motors integrated into a planetary gearbox for an overall compact solution, based on application performances and required space claims for various construction equipment machine designs.
BORGWARNER INC.
High voltage coolant and air heaters, battery packs, chargers, electric drive modules, e-turbos and boosters, fuel cell air supplies and turbine generators.
Auburn Hills, Michigan, USA
Web: www.borgwarner.com
News for BorgWarner
Lithium-ion battery system provider Akasol AG became a majority-owned subsidiary of BorgWarner Inc. in June 2021. The acquisition was expected to further strengthen BorgWarner’s commercial vehicle and industrial electrification capabilities as well as position the company to capitalize on what it believes to be a fast-growing battery pack market. Akasol’s headquarters are in Darmstadt, Germany, and will be run independently.
This move supports BorgWarner’s Project Charging Forward, which it announced during its Investor Day in March 2021. The company said that the project represents an acceleration of its electrification strategy, which is expected to bring the company’s electric vehicle revenue from less than 3% of total revenues today to approximately 45% in 2030.
The plan comprises three pillars, namely profitably scaling electric light vehicles, expanding into electric commercial vehicles and optimizing the company’s combustion portfolio.
BOSCH REXROTH CORP.
Electric motors, inverters, gear systems and control software.
Charlotte, North Carolina, USA
Web: www.boschrexroth.com
BRIGGS & STRATTON
Modular 3.8 kWh, 5 kWh and 10 kWh lithium-Ion batteries.
Milwaukee, Wisconin, USA
Web: www.basco.com & www.vanguardpower.com
The Vanguard product line from Briggs & Stratton includes gasoline engines as well as lithium-Ion battery packs
News for Briggs & Stratton
The company said MarIndustrial, and its division DAC Industrial Engines, will sell and service the full product line of Vanguard commercial lithium-ion battery packs in Canada. Marindustrial is an industrial and marine distributor whose head office is based at Montreal in Québec, Canada.
Supported by an engineering department, the company specializes in the distribution, value-added power unit solutions and service of industrial engines including Vanguard engines.
The addition of Vanguard battery packs will give industrial customers access to an electric power alternative for off-highway equipment.
Briggs & Stratton has partnered with Allen Engineering Corp. to power its new AW16-B battery-powered buggy with a Vanguard 48 V lithium-ion battery pack, which allows it to reach nine-hour run times.
The partnership developed from Vanguard’s existing relationship with Kraft Fluid Systems Inc., one of the first technology partners signed on as a distributor of Vanguard battery packs.
CATERPILLAR INC.
Production hybrid systems and concept hybrid and electric drive systems for construction and mining machinery and complete machines.
Peoria, Illinois, USA
Web: www.cat.com
News for Caterpillar
Caterpillar’s theme for the 2021 MinExpo event of “Together, we’re mining better,” will celebrate the company’s partnership with mines and the ways that it assists customers to mine efficiently, effectively, safely and sustainably.
Electric vehicles are part of the sustainability message. The company said it will show a Cat R1700 XE LHD (load-haul-dump) with 100% battery-electric propulsion. It has a 16.5 ton payload, 53,330lb lift, tilt breakout force and 11.2mph top speed.
The batteries stay on the machine for charging optimize runtime and improve safety. To fully charge the LHD in as little as 20 minutes, the company claim that the new portable Cat MEC500 mobile equipment charger is the first of its kind in the industry. It can be moved via towing, fork truck or the Cat R1700 XE plus will eliminate the need for regular battery handling and swapping.
The company signed an agreement in June 2021 with Nouveau Monde Graphite Inc. Caterpillar will develop, test and produce zero-emission machines by 2028 for the Matawinie graphite mining project in Québec, Canada.
CONCENTRIC AB
Lubricant, coolant and fuel pumps, hydraulic products encompassing gear pumps and power packs as well as pumps and other key technologies for electrical and hybrid powertrains.
Redditch, Worcestershire, England
Web: www.concentricab.com
Concentric’s electrohydraulic steering pump systems has been specified by an OEM for new battery electric delivery vehicles
News for Concentric
The company announced in June a long-term agreement with a global truck and bus OEM to supply electric coolant pumps for a heavy-duty electric truck.
Concentric currently supplies the customer with e-pumps for its hybrid and battery electric buses. This new supply agreement is expected to significantly increase e-pump volumes.
The electric coolant pump boasts a robust design that includes a wet rotor, eliminating the possibility of a dynamic seal failure, a long service life aided by liquid cooled electronics and dc brushless design along with integrated diagnostics and utilizing sensors for temperature and pressure.
Concentric stated that it will also support a North American OEM with its EHS (electrohydraulic steering system). The OEM is developing medium- and heavy-duty battery-electric trucks used in the last mile and return to base segments.
Concentric said that its EHS system has been designed, developed and tested over many years for use in a range of on- and off-road commercial vehicles. The EHS system has earned production nominations with established OEMs entering the electric vehicle market, who require e-pump expertise to replace their hydraulic steering pumps previously driven by a conventional engine.
COULOMB SOLUTIONS INC. (CSI)
Battery systems, battery integration, heavy-duty electric components including dc-dc converters, on-board chargers, battery chillers, power steering pumps, water pumps, heaters, 150 kW dc fast chargers and ac vehicle chargers, ethanol range-extenders and hydrogen-ethanol fuel cells.
Livermore, California, USA
News for CSI
The company is the North American distributor for CATL commercial vehicle battery systems. In addition to CATL’s commercial vehicle LFP (lithium iron phosphate) battery technologies (cycle life rated to 4,000 cycles), the company has launched additional LFP battery systems, including long-life (8,000 cycles) and super long-life (12,000 cycles) battery offerings.
CSI and CATL have revealed that they are partnering to launch a US facility for the production and assembly of commercial vehicle batteries by 2023.
CUMMINS
Electrified power technologies and products, including battery electric powertrain, fueling stations and MW scale energy storage, hydrogen fuel cells, PEM and alkaline hydrogen generators for industrial processes.
Columbus, Indiana, USA
Web: www.cummins.com
News for Cummins
The New Power Segment, which includes Cummins’ electrified power and hydrogen portfolios, represents the company’s investment in future technologies to deliver value and prosperity for its customers and communities using materials and technologies that have less impact on the planet. New Power has developed and acquired significant capabilities in electrified powertrains, battery design and assembly, battery management, fuel cell and hydrogen generation.
DANA INC.
Maumee, Ohio, USA
Web: www.dana.com & www.danatm4.com
Vehicle integration and engineering, hybrid-electric architectures for Class 8 vehicles, complete e-powertrain systems, complete e-axles, e-drive systems, e-gearboxes, e-hub drives, e-transmissions, electric motors, motor/inverter systems, inverters, on-engine generators and e-motion systems for work circuits, control systems, thermal management solutions including battery cooling plates and electronics cooling.
Dana Class 8 hybrid system Dana’s hybrid system for Class 8 trucks
Dana this year unveiled an expanded family of Dana TM4 SUMO HP electric motors and inverters, including the HV1000 and HV2500.
The TM4 SUMO family is designed for battery-electric, range-extended and fuel-cell vehicles. These high-performance motors and inverters are engineered to offer maximum flexibility, enabling direct-drive, series-hybrid or parallel-hybrid applications.
Seth Metzger, senior vice president of electrification at Dana, explained: “The demands of urban delivery trucks, city buses, long-haul trucks and other high-power on- and off-highway vehicles require electrified solutions that meet their demanding duty cycles.
“A compelling combination of compact design and heavy-duty power, the TM4 SUMO HP series is precisely engineered to address the requirements of Class 6 through 8 commercial vehicles.”
Reaching up to 800 V dc, the TM4 SUMO HP series offers up to 430 kW of continuous power and 540 kW of peak power, as well as a peak torque value of 2500 Nm.
The company stated that it is designed to match the efficiency map of an internal-combustion engine when used as a range extender, and can reduce operating costs by more than 35% when compared with a conventional diesel-powered vehicle.
Dana said that the series uses a motor with compact concentric winding technology to deliver maximum torque density, and leverages its internal permanent magnet technology for optimal efficiency and cost. TM4 SUMO HP technology has been combined with Dana’s field-proven axle designs to support e-Powertrains for heavy-duty vehicle applications.
DANFOSS EDITRON
Motors (permanent magnet synchronous technology or synchronous reluctance assisted-permanent magnet technology) with a power capability of between 30 kW to 6000 kW, converters, traction systems, fuel cell compressor systems designed for automotive, medium-duty and commercial bus applications for up to 150 kW fuel cell stacks.
Longmont, Colorado, USA
Web: www.danfoss.com
Sporting an historic brand and a retro design, the FNM 833 delivery truck is fully electric and uses a drivetrain system from Danfoss Editron
News for Danfoss Editron
The Danfoss Editron, Meritor and Electra Commercial Vehicles have formed a consortium called Electric Powertrain Integration for Heavy Commercial Vehicles (EPIC).
Through the EPIC partnership, the three members will design and develop an electric powertrain system. This will use a high-power electric motor and high-efficiency silicon carbide inverter delivered by Danfoss Editron and a three-speed transmission, geared differential and lightweight brakes provided by Meritor. Electra Commercial Vehicles will be responsible for the integration of the battery-electric chassis and to build four different chassis for validation.
Danfoss Editron said its motor will be based on a patented architecture and thermal management methodology and that only one motor will be required in the electric powertrain design, at a time when existing products need two motors to meet the product segment’s power requirements. Using one motor is seen as a step-change in the industry, as it will lead to a reduction in parts, weight and cost.
Danfoss Editron also stated that it is powering fully-electric trucks for one of Brazil’s largest fleets as Brewer Ambev has partnered with Brazilian EV specialist FNM.
FNM selected in late 2020 for Danfoss Editron’s drivetrain systems to power the FNM 833 electric truck. Pre-series vehicles are making deliveries in Rio de Janeiro, Brazil. Ambev has revealed that it expects to add 1,000 FNM fully electric trucks to its fleet.
Danfoss Editron also joined forces with the Ship and Ocean Industries R&D Center, a Taiwanese government institute, to launch the Green Energy Application Development Center in Taiwan. The new center will showcase a new electric marine dc power grid jointly developed by both companies as well as serve as a learning platform to marine professionals from the Asian-Pacific region.
OMNI POWERTRAIN TECHNOLOGIES
Electrically driven planetary and parallel shaft gearboxes, permanent magnet axial flux motors and generators, IGBT and SiC MOSFET based motor control units and geared transmissions.
Houston, Texas, USA
Omni Powertrain Technologies’ Ve34/M27P8 combination electric drive
News for Omni Powertrain Technologies
The company’s latest addition to its growing range of electric drives is the Ve34/M27 combination, which includes a double reduction planetary driven by a liquid-cooled axial flux permanent magnet motor produced by Omni’s Magelec Propulsion group.
It is offered as an alternative to hydrostatic drives for applications that require medium torque outputs. Potential applications include vehicles for specialized transport such as self-propelled transporters and mobile gantry cranes.
The Ve34/M27P8 combination electric drive includes a gearbox with maximum intermittent torque of 25,000 Nm and a gear ratio of 53:1 (others available) and maximum input speed of 3800 rpm. The electric motor has a maximum speed of 4500 rpm at 48 V and peak torque of 580 Nm.
PMP INDUSTRIES INC.
Drives for electric vehicles, electric motors, integrated controllers, travel drives for wheeled applications, travel drives for tracked applications, integrated travel drives, swing drives for rotating systems, integrated swing drives for hydraulic excavators and variable displacement hydraulic motors.
Cincinnati, Ohio
The PMS625 drive from PMP is designed for electric vehicles
News for PMP Industries
The company has been involved with electric traction systems since the 1990s, when it introduced the PMS product range for electric forklift and electric towing tractors.
The drive for integration and innovation has led to the introduction of high-speed integrated motors with speeds up to 10,000 rpm, reduced copper content and unrivalled sound performance, said PMP.
The compact packaging of the drives has paved the way for the introduction of PMP integrated controller drives, with robust components, integrated speed sensor and several new features optimized for off-highway mobile systems. The company claimed that this provides value in terms of reduced harnessing, compactness, ease of installation and serviceability,
PMP offers complete systems, combining its Electric Vehicle Driveline Divison electric motors with the gearing products of the Power Transmission Division.
T/CCI MANUFACTURING
Electric and belt-driven compressors for heating and cooling batteries and cabs.
Decatur, Illinois, USA
Website: www.tccimfg.com
T/CCI’s large electric compressors are designed for battery cooling and air conditioning in the heavy-duty trucking, bus and railway sectors
News for T/CCI Manufacturing
The company said its new Advanced Testing Center (ATC) in Decatur, Illinois, will help it develop and optimize customer systems. The center allows it to test heating, air conditioning and battery heating or cooling systems.
Dick Ennis, engineering director with T/CCI, said, “We have a very extensive suite of equipment in the ATC, including electric compressor durability test benches.”
The company introduced a range of new compressors in February 2021, which include high-voltage electric designs from 15cc/24V to 120cc/850V and 2 kW to 30 kW. The 400V to 850V products are designed for vehicles propelled by an electric motor including heavy-duty trucks, buses and transport refrigeration vehicles.
The 120cc/850V compressor is designed to provide battery cooling and air conditioning for heavy-duty truck, bus and rail. The 24V products cool the interior of a cabin when a vehicle’s engine is turned off and is available now. The larger 850V compressor is expected to hit the market this fall.
Ennis added, “We are investing a lot on electrification, and we already have a plethora of models developed and have some very robust new models under development.
“I think the preponderance of compressors within the next five to six years are going to be electric because the vehicles are going that way.”
T/CCI said that it was named a Diamond Supplier by Navistar International Corp. for the fourth consecutive year In June 2021, and that it was proud to support the truck and bus builder as it continued to “launch new products and make progress on ambitious endeavors, including plans for a full electrification solution that includes charging, route planning and infrastructure”.
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