The XV3300 Multi-Function Charging System: Filling the Market Gap for Compact Mobile Machinery Electrification
Original equipment manufacturers (OEMs) and their partners contending with electrification challenges for mid-power, compact non-road mobile machines (NRMM) made substantial gains in recent years. Solutions for overcoming power output requirements and work environments make electrification and zero-emissions operation possible in applications previously considered too difficult or costly.
However, despite compact NRMM’s electrification, this recent push for electric mid-power machines directs OEMs into largely unexplored territory regarding chargers. Solutions like Delta-Q Technology’s XV3300 charging system are necessary to address the market gap.
The On-Board Charger Market Gap for NRMM
Locked in a decades-long competition over improving internal combustion engines (ICEs) and related systems, the only concern in powering NRMM had been the on-site or nearby presence of gas or diesel. Now, OEMs need a solution that outfits NRMM with sufficient recharging capabilities.
Simply put, mid- and high-power applications require larger, higher-performance batteries, which—in turn—require higher-performance chargers. And, with their efforts previously directed elsewhere, most OEMs discover a glaring lack of on-board chargers that meet their new requirements for competing in this emerging market.
Examining Compact NRMMs On-Board Charger Requirements
Like all charging challenges, different types of compact NRMM benefit most from application-specific solutions or charger configurations. However, they still share many requirements:
- On-board chargers – For most NRMM applications, on-board chargers and the opportunity charging they enable is essential.
- Lithium battery compatibility – One of the drivers behind electrification is the transition to lithium batteries. However, some operations may still utilize lead-acid batteries or both simultaneously, which requires dual-support chargers.
- 2-11 kW output and fast-charging capabilities – Via greater power output and fast charging, chargers must ensure battery capacity is available when needed.
- Battery pack and BMS communication – NRMM chargers require more sophisticated integration and data communication (e.g., telematics) between the battery pack and the battery management system (BMS) for optimal charging control and performance.
- Industrial power outlet or EVSE compatibility – Replenishing greater battery capacity necessitates connections to higher-voltage inputs than residential outlets—either via industrial outlets or standard electric vehicle supply equipment (EVSE).
- Small size – On-board chargers must fit on NRMM and equipment already designed to be compact. Space remains a premium that chargers must adapt to.
- Ruggedness and reliability – On-board chargers for NRMM must be protected against significant stress (e.g., off-road terrain, impacts, liquids) to ensure long lifecycles and optimal component performance.
- Charge quality – Ensuring batteries attain their maximum lifecycle requires chargers capable of delivering consistent quality for that duration (and monitoring any signs of potential failure).
- Machine integration support and customization – More complex NRMM designs and engineering necessitates integrated chargers, which may require greater customization.
- Regulatory approval – Chargers must meet demanding international standards for safety, power supply connections, electromagnetic interference, and more.
- Manufacturing quality and scale – OEMs need the confidence that their partners will design, engineer, and manufacture chargers that maintain quality at scale to preserve product and OEM reputations, particularly when entering a new market.
Delta-Q Technology’s XV3300 Charging Solution
Delta-Q Technologies designed the XV3300 charging system to meet this market gap and the requirements listed above.
3-in-1 Compatibility
The XV3300 provides three different interfaces to ensure compatibility with any power source operators and fleet managers might have available. For industries like construction, agriculture, and outdoor power equipment (OPE), the greater likelihood of power source limitations necessitates broader compatibility. Additionally, combining multiple charging interfaces reduces unit size significantly (e.g., overall volume, components, cables).
The XV3300 system can recharge any battery chemistry (e.g., lithium chemistries, lead-acid) via:
- AC/DC conversion – Virtually all battery chargers require AC/DC conversion. Power distribution grids worldwide use alternating current (AC) to deliver electricity, but that current must be converted to DC for battery storage and use.
- DC/DC conversion – Auxiliary batteries used to power accessories (e.g., lights, turn signals, navigation, communication) may need to draw power from the primary battery to support those functions. The XV3300 can provide up to 500W of DC/DC converted power to ensure important auxiliary functions remain operational.
- EVSE – Available electric vehicle (EV) charging infrastructure will only increase following ongoing government investment, which is instrumental to providing readily available power sources wherever work sites are located. The XV3300’s compliance with the SAE J1772 (Level 1 and 2) and IEC 61851 EVSE standards ensures charging station compatibility across North America and Europe.
Meeting Higher Charger Output Demands and Size Constraints
Based on the IEC 60038 standard, the mid-power class falls between 1 and 35V. Most NRMM and other machinery classified as mid-power require chargers that can deliver between 2 and 11 kW.
A single XV3300 charger can provide up to 3.3kW, making it compatible with applications on the lower end of this mid-power range. But to further extend utility for applications requiring larger battery packs, Delta-Q Technologies developed sophisticated software enabling OEMs to “stack” up to three XV3300 chargers or place them in parallel sequence—achieving a maximum of 10kW.
Aside from increasing charger output levels, outfitting machines with redundant chargers also provides greater resiliency against potential system failures.
Multiple XV3300 chargers do not need to be placed in the same location to support this parallel operation. And because of their efficient size (11.8” x 8” x 4.3” / 300mm x 204mm x 110 mm, 15.4lbs / 7kg) and mounting flexibility, OEMs can accommodate compact NRMM’s limited space by distributing the modular units in the best configuration for a given machine.
Charger Protection and Rugged Design for Demanding Environments
Delta-Q Technologies designed the XV3300 charging system to withstand the abuses doled out in the most demanding work environments.
The system’s protections help prevent short-circuit, over-voltage, and over-temperature incidents that can severely damage charger components and batteries. For example, every temperature increase of 15°F or 8°C above normal operating temperature halves a battery’s lifespan. These incidents can also jeopardize worker safety.
Regarding stresses like extreme vibrations, impacts, and temperature and humidity fluctuations, the XV3300 adheres to General Motors’ GMW3172 standard for automotive reliability. It’s also subjected to highly accelerated lifetime testing (HALT) for an expected eight-year service life to better ensure continual performance even long into use.
And Delta-Q Technologies engineered the XV3300 to withstand dirt, mud, liquids, and other contaminants likely to be within proximity of NRMM and the charging system. The charger achieved IP-66 and IP-67 ratings—making it both “dust-tight” and protected against “powerful water jets” and “temporary immersion in water”—when tested according to IEC 60529 procedures.
Based on the thoroughness of the XV3300’s engineering and testing, OEMs partnering with Delta-Q Technologies can maintain confidence that their chargers will meet whatever conditions operators throw at their NRMM (and hold up for warranty terms).
System Communications and Telematics Data
The XV3300’s flexible connectivity options and software configurations help ensure seamless battery management system (BMS) integration and rapid telematics data transfer. This enables the BMS to provide real-time charge management via CAN-control (e.g., charge rates, cell monitoring), which preserves charger and battery health and achieves longer service lives.
With the telematics data provided, operators and fleet managers remain informed about performance and upcoming maintenance well before potential issues might arise or cause substantial downtime.
The XV3300 supports both the CANopen and SAE J1939 protocols for CAN-bus data transfer.
Compliance with Global Regulatory Standards
In addition to complying with the standards mentioned above, the XV3300 charging system adheres to the following global regulations and industry standards:
- North American Safety standards certification—including the special provision for lithium battery charge testing
- European safety requirements
- North American Class B electromagnetic compatibility (EMC) emissions requirements for connection to residential power
- European safety and emission/immunity requirements for electromagnetic interference and EMC
- UNECE R10 standard for limits regarding on-board chargers’ EMI and EMC in on-road vehicles
OEMs electrifying mid-power NRMM already contend with enough new-market challenges; their partners’ compliance with international and national standards for safety, emissions, and components shouldn’t add to them.
“Charged by Delta-Q”—Charge Quality and Battery Partner Compatibility
Different OEMs establish partnerships with different—or multiple—battery providers and need the charging systems they implement in NRMM to provide the same charge quality regardless of brand. Delta-Q Technologies helps ensure that compatibility by iteratively testing and validating batteries from various partners to ensure seamless compatibility across chargers, software, and charge algorithms.
Batteries evaluated via this testing receive the “Charged by Delta-Q” label, with further specification for:
- Level 1 – “Delta-Q Charge Optimized”
- Level 2 – “Delta-Q Charge Compatible”
OEMs that choose the XV3300 charging system know they can find their ideal battery partner without risking performance. The list of providers offering batteries that earned this label includes:
- American Battery Solutions
- idneo
- Stafl Systems
- Relion
- Inventus Power
- US Battery Manufacturing Company
- Fullriver Battery
- Flux Power
- EnerSys
- Discover Battery
- Discover Energy Systems
- Beam
- Trojan Battery Company
- BSLBATT
- Aliant Battery
Closing the Market Gap for Mid-Power NRMM
Mid-power NRMM represents one of the most exciting and impactful electrification opportunities today. Numerous industries and myriad applications rely on these machines, which traditionally operate via ICE power almost exclusively. But with recent innovations, operating and charging electric-drive NRMM becomes not only possible but increasingly common.
OEMs that successfully electrify their NRMM offerings and identify the right partners stand to become major players in this emerging market. Charging capabilities has been one of the tougher challenges to solve, but Delta-Q Technology’s XV3300 significantly closes the gap.
Sources:
SAE International. SAE J1772 Electric Vehicle Adapter Standard. https://www.sae.org/sae-j1772-electric-vehicle-adapter-and-plug-standard
IECEE. IEC 61851-24:2014. https://www.iecee.org/certification/iec-standards/iec-61851-242014
StudyLib. International Standard IEC 60038. https://studylib.net/doc/18121364/international-standard-iec-60038
Battery University. BU-806a: How Heat and Loading affect Battery Life. https://batteryuniversity.com/article/bu-806a-how-heat-and-loading-affect-battery-life
- General Specification GMW3172. https://www.wewontech.com/testing-standards/190219006.pdf
IEC. IP ratings. https://www.iec.ch/ip-ratings
