Electrification of Transmission System: Hydrostatic and Electric (E-trans)
The basic idea of this project is to design a new concept of a hybrid-electric transmission system adapted to Construction Equipment (CE).
The project at a glance
About
Electrification is key for reducing CO2 emissions in road transportation. Medium and Heavy-Duty Vehicles (MHDV) contribute to greenhouse gas (GHG) and harmful particle emissions. Electric Vehicles (EV) offer benefits like higher torque density and zero local emissions, attracting interest. Challenges like limited driving range and insufficient charging infrastructure have been addressed through research and development over the past decade.
While some MHDVs are now available, construction excavators and agricultural tractors have not received the same attention despite being major pollution sources. These vehicles need environment-friendly developments in the next decade, focusing on energy efficiency and reducing GHG emissions by eliminating fossil fuels. The shift from thermal to hybrid drive systems will occur, but there are significant differences between cars and heavy-duty working vehicles. For example, regenerative cycles are ineffective in agricultural tractors because of negligible braking energy recovery in field applications. Power transmission systems in these vehicles differ in torques, operating speeds, cycles, controls, and motion degrees of freedom compared to cars. Market analysis identified systems that can be fully or partially electrified based on required power.
The current project aims to design a hybrid-electric transmission system for Construction Equipment (CE). Carraro and the UL team will develop two hybrid tractors and aim to extend electrified transmission and transaxle systems to construction equipment. CARRARO Lux-Tech R&D proposes an innovative two-speed e-transmission system for construction equipment (Compact Wheel Loader CWL, Telehandler THL, Backhoe Loader BHL) and agricultural vehicles (AG) up to 13 tons, with equivalent diesel engines between 55kW and 90kW and a maximum speed of 45km/h, requiring high traction force and top speed.
To sum up, the E-Trans project will focus on:
- Mechanical design from new transmission architecture research and mathematical modelling for optimal efficiency.
- A product installable in existing vehicles in different configurations (horizontal or vertical).
- A product for customers using conventional hydrostatic drives or those transitioning to electric vehicles.
- Research and development of adaptable electrical drives with new materials and components.
- Development and patenting of new software control algorithms for fast-shifting times and minimal power loss.
Organisation and Partners
Carraro Lux-Tech R&D Centre
Project team
