Periodic Reporting for period 2 - Electric Actuator (Electrification of heavy machinery)
Periodo di rendicontazione: 2024-07-01 al 2025-05-31
With increased focus on climate change and expanding regulatory efforts to control CO2 emissions, many industries, particularly the mobile machinery industry, are undergoing a transformative shift towards electrification.
The primary objective of our project at Excess Engineering is to address a critical bottleneck in this transition: the inefficiency of hydraulic systems in electrically powered machinery. Despite advancements in electric motor and battery technology, the persistence of traditional hydraulic systems significantly undermines overall efficiency. Our project aims to replace these outdated hydraulic systems with innovative electromechanical solutions, specifically designed for heavy-duty applications such as construction machinery.
The pathway to impact for this project is twofold:
• Technological Innovation: We have developed a state-of-the-art electric actuator capable of handling loads up to 120 tons with a stroke of up to 3 meters. This technology not only matches the power and size of existing hydraulic systems but also significantly reduces energy losses, thereby enhancing the overall efficiency of the machinery.
• Operational Efficiency and Sustainability: By integrating our electric actuators into mobile machinery, we expect to see a substantial increase in operational efficiency. This improvement is crucial for machines operating in remote areas where battery recharging options are limited. Additionally, the reduced need for larger batteries will decrease the initial costs and the overall weight of the machinery, further enhancing operational efficiency and reducing environmental impact.
The expected impact of our project is significant on multiple fronts:
• Environmental: By enhancing the energy efficiency of electric machinery, our project contributes directly to reducing CO2 emissions, aligning with EU's climate goals.
• Economic: The adoption of our technology is expected to reduce operational costs for OEMs and end-users, fostering broader economic benefits.
• Strategic: Our project positions the EU at the forefront of innovative and sustainable heavy machinery technology, reinforcing its strategic objective of leading in green technology globally.
In conclusion, our project is not just a technological leap but a comprehensive solution addressing environmental, economic, and strategic needs in the context of the EU's policy priorities. It sets a new standard for efficiency and sustainability in the heavy machinery sector, paving the way for a more environmentally conscious and economically viable future.
The primary objective of our project at Excess Engineering is to address a critical bottleneck in this transition: the inefficiency of hydraulic systems in electrically powered machinery. Despite advancements in electric motor and battery technology, the persistence of traditional hydraulic systems significantly undermines overall efficiency. Our project aims to replace these outdated hydraulic systems with innovative electromechanical solutions, specifically designed for heavy-duty applications such as construction machinery.
The pathway to impact for this project is twofold:
• Technological Innovation: We have developed a state-of-the-art electric actuator capable of handling loads up to 120 tons with a stroke of up to 3 meters. This technology not only matches the power and size of existing hydraulic systems but also significantly reduces energy losses, thereby enhancing the overall efficiency of the machinery.
• Operational Efficiency and Sustainability: By integrating our electric actuators into mobile machinery, we expect to see a substantial increase in operational efficiency. This improvement is crucial for machines operating in remote areas where battery recharging options are limited. Additionally, the reduced need for larger batteries will decrease the initial costs and the overall weight of the machinery, further enhancing operational efficiency and reducing environmental impact.
The expected impact of our project is significant on multiple fronts:
• Environmental: By enhancing the energy efficiency of electric machinery, our project contributes directly to reducing CO2 emissions, aligning with EU's climate goals.
• Economic: The adoption of our technology is expected to reduce operational costs for OEMs and end-users, fostering broader economic benefits.
• Strategic: Our project positions the EU at the forefront of innovative and sustainable heavy machinery technology, reinforcing its strategic objective of leading in green technology globally.
In conclusion, our project is not just a technological leap but a comprehensive solution addressing environmental, economic, and strategic needs in the context of the EU's policy priorities. It sets a new standard for efficiency and sustainability in the heavy machinery sector, paving the way for a more environmentally conscious and economically viable future.
Our project has made considerable progress in qualification test preparations and two pilot projects, each targeting a unique application of our electric actuator technology:
1) Electric Drive for Subsea Applications:
This pilot aims to demonstrate the effectiveness of our electric actuator in subsea environments. In this project, the electric actuator is used in an electric hoisted mast for raising and lowering an antenna.
Activities performed and the main achievements:
• Compact linear actuator design and manufacturing is completed
• Control software has been developed.
• The actuator is assembled and tested.
• Valuable learning on strict noise limit requirements for the application.
2) Test platform for validation:
This activity involves building two actuators and setting them up to work against each other and perform endurance testing to verify estimated service life.
Activities performed and the main achievements:
• Actuator components procured and produced 90% complete by 31.05.2025.
• Test jig, control system and software is ready for testing.
• Testing scheduled to start 11.08.2025
3) All-Electric Wheel Loader:
This pilot involves converting a diesel-powered Volvo L110H wheel loader with hydraulic systems into an all-electric version using our custom-designed electric actuators.
Activities performed and the main achievements:
• Significant effort has been needed to produce geometrical information, interface drawings and control system interfaces (cause of delay).
• Detail design of actuators and system design for converting a diesel hydraulic wheel loader to fully hydraulic-free battery-electric has been completed, including a novel patented compact bearing solution.
• The diesel engine, radiator and hydraulic system has been removed from the Wheel Loader.
• Testing of electrical system and cooling system completed in workshop prior to installation on the Wheel Loader.
• Control system has been designed, software architecture established, and software development is ongoing.
• Selection and procurements of control system components and motor controllers are completed.
• Procurement and manufacturing of actuator components 50% complete by 31.05.2025
1) Electric Drive for Subsea Applications:
This pilot aims to demonstrate the effectiveness of our electric actuator in subsea environments. In this project, the electric actuator is used in an electric hoisted mast for raising and lowering an antenna.
Activities performed and the main achievements:
• Compact linear actuator design and manufacturing is completed
• Control software has been developed.
• The actuator is assembled and tested.
• Valuable learning on strict noise limit requirements for the application.
2) Test platform for validation:
This activity involves building two actuators and setting them up to work against each other and perform endurance testing to verify estimated service life.
Activities performed and the main achievements:
• Actuator components procured and produced 90% complete by 31.05.2025.
• Test jig, control system and software is ready for testing.
• Testing scheduled to start 11.08.2025
3) All-Electric Wheel Loader:
This pilot involves converting a diesel-powered Volvo L110H wheel loader with hydraulic systems into an all-electric version using our custom-designed electric actuators.
Activities performed and the main achievements:
• Significant effort has been needed to produce geometrical information, interface drawings and control system interfaces (cause of delay).
• Detail design of actuators and system design for converting a diesel hydraulic wheel loader to fully hydraulic-free battery-electric has been completed, including a novel patented compact bearing solution.
• The diesel engine, radiator and hydraulic system has been removed from the Wheel Loader.
• Testing of electrical system and cooling system completed in workshop prior to installation on the Wheel Loader.
• Control system has been designed, software architecture established, and software development is ongoing.
• Selection and procurements of control system components and motor controllers are completed.
• Procurement and manufacturing of actuator components 50% complete by 31.05.2025
The development of our electric actuator technology stands out due to its high energy efficiency, positioning it as a critical enabler for industries transitioning from heavy-duty hydraulic systems to more sustainable electric alternatives. The potential impacts of this technology are substantial, offering a greener, more efficient solution for sectors like construction and mining.
Our immediate priority is to run qualification testing and finalize two main pilot projects. Successful demonstrations will validate the technology's robustness, safety, and performance, thereby building trust and credibility among potential customers. Collaborations with established players in the target industries can accelerate our market entry, enhance our visibility, and expand our customer base.
Supportive regulatory and standardisation framework addressing the enormous energy waste by traditional construction machines through hot exhaust and radiators would encourage the implementation of the energy efficient electric actuators.
The development has resulted in novel patented bearing solution which enables a compact actuator design with comparable size envelope in length and stroke to that of hydraulic cylinders.
In addition, the high load capacity has required novel lubrication and cooling solutions to dissipate heat during operation, albeit the high efficiency of the actuators.
Our immediate priority is to run qualification testing and finalize two main pilot projects. Successful demonstrations will validate the technology's robustness, safety, and performance, thereby building trust and credibility among potential customers. Collaborations with established players in the target industries can accelerate our market entry, enhance our visibility, and expand our customer base.
Supportive regulatory and standardisation framework addressing the enormous energy waste by traditional construction machines through hot exhaust and radiators would encourage the implementation of the energy efficient electric actuators.
The development has resulted in novel patented bearing solution which enables a compact actuator design with comparable size envelope in length and stroke to that of hydraulic cylinders.
In addition, the high load capacity has required novel lubrication and cooling solutions to dissipate heat during operation, albeit the high efficiency of the actuators.