The electrification of mobile vehicles and machinery offers significant benefits, including improved efficiency, reduced emissions, and enhanced control systems. However, your electric powertrain design requires careful planning and precision, starting with a thorough information-gathering process. For engineering teams, this stage is essential to ensure that the final solution meets the exact operational needs of the vehicle or machine.
Understanding the operational parameters of the system is key to designing an electric powertrain that will deliver the required performance. At Lancereal, this process begins with an extensive application questionnaire, aimed at capturing the unique specifications and challenges of the project. The data collected in this phase allows our engineers to tailor the electrification process to the machine’s exact needs.
Key areas of focus include:
- Vehicle type and application
- The nature of the vehicle or machine is one of the most important factors to consider, as the operational demands will vary depending on function. The environment in which the vehicle operates (e.g., off-road terrain or factory floors) and the duty cycles will influence the powertrain’s design and effect decisions around the most appropriate parts for the motor size to the control system.
- Weight and distribution
- The weight of the vehicle, including how that weight is distributed, has a direct impact on motor sizing and powertrain configuration. Heavier vehicles demand more torque, while uneven weight distribution may require more sophisticated control systems to maintain balance and efficiency across all wheels.
- Wheels and surface interaction
- Understanding how many wheels the vehicle has, and what surfaces it will be driving on, is essential. For example, vehicles that operate on rough terrain or with varying load conditions will require different torque outputs and drive systems compared to those used on smooth, even surfaces.
Technical performance specifications
It is important to gather data on the vehicle’s torque, speed, and power requirements. How fast does it need to travel? How much torque is required for acceleration or climbing inclines? This information ensures that the selected electric motor and gearbox can meet the vehicle’s operational demands without overloading the system.
Functional specification & Safety considerations
Getting a clear picture of how the vehicle or machine will operate is essential to ensure the control systems and programming are up to the task. This involves looking at not just how the vehicle functions but also how safe and user-friendly it is for operators. For example, in a wheel-drive application, we’d explore:
- Speed Control: How is the speed managed? Does it need a throttle, fast/slow modes, or set speeds?
- Steering Systems: What kind of steering does it have? Is it skid steering, electric power steering, or something else? Are there sensors to help monitor and control it?
- Data Displays: Does the machine need to show things like battery levels, speed, or hours in use?
- Hydraulics: Are hydraulic pump motors needed for functions like lifting or steering?
- Battery Tech: What type of battery is being used, and how does that impact the system?
- Safety Features: Are there requirements for emergency stop systems, overload protection, or operator alerts? These features are vital to ensure the machine operates safely in all conditions.
- Operator Conditions: Will the vehicle be operated manually, remotely, or autonomously? If remote control is required, what kind of system is needed to ensure seamless and reliable operation?
By digging into these details early on, we can make sure the control systems are designed to work exactly as needed. It’s all about creating an electric powertrain that fits how the vehicle or machine is meant to work, making it as efficient and reliable as possible.
Why Information Gathering is Crucial
Accurate data collection is critical because it defines the framework for the entire electrification project. Without precise information on vehicle specifications, it becomes nearly impossible to design an electric powertrain that will function optimally. Incorrect or incomplete data can lead to underperformance, energy inefficiencies, or, in the worst cases, system failure.
It’s also important to recognise that with new machine designs, engineers often learn and adapt throughout the process, leading to new ideas and changes as the project evolves. Our role is to provide flexibility while ensuring effective change management every step of the way.
Tailoring the Solution
Every vehicle is unique, and so too are its power requirements. Gathering detailed information enables our engineers to run accurate calculations and select components that are specifically suited to the vehicle’s operational environment and tasks.
Safety is a critical consideration throughout this process. Different applications often come with specific regulations and standards that must be met, whether they involve vehicle performance, operator safety, or environmental compliance. By factoring these requirements into the design, we can create systems that are not only efficient but also fully compliant with industry and legal standards.
Operator comfort is another key aspect. From smooth controls to noise reduction and ergonomic design, a well-thought-out powertrain can significantly enhance the user experience. Whether it’s a vehicle being manually operated or one controlled remotely, considering the operator’s environment ensures the solution is practical, intuitive, and comfortable to use
Information gathering is not just the first step in electrifying a product – it’s the most important one. By investing the time to gather accurate, detailed information about a vehicle’s operational needs, Lancereal can ensure that the final electric powertrain solution is optimised for efficiency, performance, and reliability.
Through our comprehensive approach, we often uncover considerations that might not have been identified before, especially for engineers accustomed to working on combustion engine vehicles. Asking the right questions helps us address potential challenges early on, paving the way for a smoother and more effective electrification process.
Whether you are electrifying a fleet of vehicles or a single machine, the process starts with understanding the unique challenges and requirements of your application. Our structured approach to information gathering to provide data-driven recommendations ensures that your electric powertrain is built on a foundation of accuracy and precision, delivering long-term benefits in both performance and sustainability.