Off-highway vehicles have long operation times and require high amounts of power to operate at their fullest capacity, making efficient and safe electrification a major obstacle, but modular battery packs may be the solution.

Off-highway vehicles require huge amounts of power, thus making them difficult to electrify, as they require very large battery packs and regular access to a grid connection. One of the key challenges is that for electric machines to operate for the same length of time as their diesel-powered equivalents, they require a huge battery pack. A modular battery is a battery pack that has been designed to work in tandem with other battery packs of the same specification. By introducing or reducing batteries in a modular setup, those using off-highway vehicles will be able to fulfil power requirements without being limited to a set capacity or voltage.

Modular batteries are easy to replace. If one of the modules fails, you can directly replace that module instead of scrapping the entire battery system; the failure of one module will not impact the system or the site operation. They also have superior heat dissipation; with a good battery management system, modular batteries will dissipate heat much better than a single large battery pack. Use of a modular battery management system (BMS) can be utilised to protect lithium-ion batteries from overcharging and deep discharge, as well as balancing the cells in a battery pack to ensure optimal performance and longevity.

Eleo, a previous Innovatrix partner, has introduced a new range of battery packs specifically designed for off-highway applications. They have a flexible, modular design that accommodates space constraints, with both horizontal and vertical placement options. These battery packs offer a scalable voltage range from 50V to 720V and a maximum continuous power output of up to 90kW, providing a range of power potential and versatility for a wide range of applications. The multipack functionality allows multiple packs to be combined, enhancing system capacity and voltage with flexible integration in two orientations (90-degree rotation). Eleo off-highway modular batteries follow Industry Standard Protocols, utilising CANOpen and J1939 communication protocols for integration and providing essential data for safe and reliable operation. They have a service-friendly interface box, minimising service turnaround time with a design that allows for easy and quick part replacement and eliminating the need to ship complete batteries back for repair. These battery packs enable simple, fast integration to support off-highway OEMs in electrifying their entire product line with the same range of battery packs.

Past Innovatrix partner Webasto also offers modular battery options for commercial vehicles with a design that can be used on any vehicle platform for total scalability and configuration flexibility. Each battery pack has a compact, energy-dense format with 35 kWh of energy, and up to 10 packs can be used for a combined 350 kWh. The battery packs can be easily configured via the vehicle interface box (VIB), which is the master battery management system and power distribution unit. The modules are self-contained and include desiccant cartridges that reduce condensation. They have integrated thermal runaway detection sensors and state-of-the-art pressure equalisation monitors to ensure safety.

Modular batteries can be used to scale the power of a battery pack up or down to suit the requirements of the end-user. They are also a safer alternative to large-voltage battery packs that are prone to overheating due to the immense power needs required by an off-highway vehicle in continuous use. Modular battery solutions and other innovations, as well as challenges facing the electrification of off-highway vehicles, will be discussed at the Innovatrix event, the DZOM EXPO, taking place at the Donald E. Stephens Convention Centre in Chicago, IL, on December 3–4, 2024.

For more information, visit our website or email us at info@innovatrix.eu for the event agenda.