Electric Machinery and Vehicles

Electric Machinery and Vehicles

There are many promising applications with great electrification potential, this includes a great number of commercial vehicles or mobile working machines that are already operated without a combustion engine. Particular attention is being paid to vehicles and machines that are used in urban spaces, such as municipal machines and compact construction machines. Moreover, large and powerful machines are also being electrified, such as those used in mining and in ports and airports.

For all these machines and vehicles, HYDAC supplies an extensive portfolio of components and systems for applications relating to the battery system, thermal management, energy-efficient working drive units and hydrogen and fuel-cell technology.Furthermore, our TTControl controller family is perfect for use in electrified machines and vehicles.


Controllers and software

TTControl, a joint venture of TTTech and HYDAC International, supplies safety-certified high-power controllers and powerful inexpensive mid-size controllers for applications that need to function reliably under tough ambient conditions, as well as corresponding robust user interfaces with various screen sizes from 7" to 12".

In the context of electromobility, our controllers are ideal for use as VCUs (vehicle control units), DCUs (drive control units), FCCUs (fuel cell control units), in battery management systems (BMS) or in thermal management systems.

To complement our hardware, with MATCH we offer an innovative, efficient and TÜV-certified tool for the development and maintenance of safety-related control software for mobile working machinery. MATCH offers you optimally coordinated solutions over the entire lifecycle: from planning right up to service. Functional safety included. With MATCH, the actual functional development of the machine is carried out in a standardised, freely available development environment. 


Thermal management

The term thermal management refers to the energy optimisation of the heat balance in electrified mobile working machinery or an electrified commercial vehicle with the aim of achieving consumption and emission reduction. Almost all the technical conditions are changing in terms of the temperature ranges, heating/cooling power, the number of heating/cooling tasks and the fluids used. The variety of coolants ranges from water glycol to special electrically non-conductive fluids such as transformer oils and demineralised water (DI-water), which is used in particular in the cooling of fuel cells.

Cooling on board electrified machinery is required in particular for electric components such as electric motors, power electronics systems (drive unit frequency converters, DC/DC converters and charging devices), batteries and fuel cells. Furthermore, the driver’s cab and the batteries need to be heated up under certain conditions. 

Passive coolers and cooling systems

Passive coolers and cooling systems

Active cooling systems (chillers)

Because high-energy lithium-ion batteries have an especially limited comfort range, they are normally cooled with an active cooling system – that is, a system with a cooling compressor (chiller). In addition to customised developments, we can supply a modular system with various levels of cooling power and various supply voltages. As an option, these cooling systems can be equipped with high-voltage heaters that can quickly provide required heat energy, for example to warm up the battery.


Active cooling system


Hydrogen and fuel cells

In mobile applications where large amounts of energy and high levels of power are required over a prolonged period, in such cases, the fuel cell used in conjunction with high-pressure tank systems for hydrogen is an effective way to drive and work with zero local emissions. For mobile fuel cell applications and tank systems, HYDAC supplies innovative solution strategies for cooling systems, mounting technology, sensors and filtration. For filling fuel cell vehicles and machines with hydrogen, HYDAC supplies additional components and systems.

Hydrogen and fuel cells

Mounting technology for tank systems

To transport the hydrogen needed for the fuel cells, type-3 or type-4 containers are currently used, depending on the application. With our unique flexible stainless steel straps with patented quick release bolts combined with individually developed neck mounts, we can realise mounting systems that allow the containers to expand and contract while keeping them securely held in the event of impact.

 

Mounting technology for fuel cell stacks

Alongside mounting high-pressure tanks, we also use our clamping band solutions in the immediate surroundings of the fuel cell. In these applications, the conventional threaded rods that apply the pressing forces to the seals of the fuel cell are replaced with clamping bands. This makes it possible to realise more even pressing forces and improve the leaktightness of the stack. We will be happy to help you in dimensioning and designing the head plates and base plates of your fuel cell.

Mounting technology for fuel cell stacks


Hydrogen filters for mobile applications

Particles entering the fuel-cell vehicle often have serious consequences for the functionality of the tank components and the fuel cells. The most prevalent problem is damage to seals and seal seats of the valves, which can cause leakage and thus failure of the tank system. Drawing on its experience in developing filter systems for hydrogen filling stations, HYDAC can offer filter solutions for protecting components in the tank systems of fuel cell electric vehicles. The HYDAC Chemicron® filter material used provides defined filtration rates and maximum filter integrity.

Hydrogen filters for mobile applications

Pressure sensors for hydrogen for mobile applications

With over 30 years of experience in pressure sensor development and production, HYDAC Electronic has established a new series of hydrogen pressure sensors on the market. Thanks to HYDAC’s in-house manufacture of the pressure measurement cell, it was possible to develop a hydrogen cell based on stainless steel.

 

Energy-efficient working drive units

HYDAC supplies solutions in the form of components, subsystems and services relating to increasing efficiency in the drive train. Drawing on decades of experience in component development, HYDAC has established itself in recent years as a reliable partner for efficient drive systems, with the development of hydraulic hybrid systems.

Variable-speed compact power units

Highly integrated hydraulic power units that enable efficient and decentralised supply of hydraulic auxiliary equipment.

Variable-speed compact power units