The DZOMUSA took place from the 3rd to 4th of December, with attendees from all over the zero-emissions off-highway machinery industry coming together in Chicago, Illinois at the Donald E. Stephens Convention Center. The two day conference had a wide and comprehensive agenda that involved dozens of presentations from expert speakers, panel discussions, fireside chats workshops and networking breaks. 

Our attendees discussed the challenges and opportunities related to developing new technologies, advancements in electric, hybrid, and alternative powertrains, integrating drives, energy management, and emphasising the significance of sustainability.

This article will provide a session recap for those who didn’t get the chance to attend and serve as a reminder for those who attended.

Day One

Don’t electrify everything

Dale Glubrecht, Director of Advanced Vehicle Technology at Alamo Group

Dale shared the Alamo Group’s portfolio of industrial vehicle manufacturers, creating products focused on infrastructure customers’ year-round maintenance requirements. Dale reviewed one of these products, the fully electric, battery-operated street sweeper after one year in use. It received positive feedback from customers and used less energy but the use of electric actuators over hydraulic came at a price. Dale concluded that hybridisation strikes the best balance between emissions and performance. The hybrid parking lot sweeper offered smooth power delivery, plug-in capability, higher sweep efficiency and no loss in performance. However, they come with infrastructure challenges and range anxiety despite their low energy use and controllability.

Hydraulic Systems for Electric or Hydrogen-Powered Working Machines

Rafael Cardoso, Engineering Manager at Bosch Rexroth

Rafael spoke about how the advent of electrification has led to a shift in priorities regarding machine system design thereby leading to a transformation of hydraulic components, systems, and control algorithms. Hydraulic systems using Multi Pressure Rail (MPR) for hydrogen engines decouple the supply side from the actuators for optimised engine usage, with pressure rails covering peak transients on average engine power and studies showing up to 55% increase in efficiency. Hydraulic systems for electrified machines can use optimal speed strategy, constant speed strategy and minimal speed strategy.  He forecasted that multiple technological advancements will play a key role in the future market, a system and holistic approach should be considered for new technology adoption and that design must evolve from application requirements.

Powering Progress: Advancing Through the Electrification Journey

Benny Forsman, Business Development Director at ZAPI GROUP

Benny shared his knowledge on the evolution from incumbent drive to electric drive with a focus on drive systems and battery charging systems. He gave the key do’s and don’ts of electrification projects. The do’s included having a plan beyond making the machine electric, engaging suppliers early and often, designing and spec for the system, considering both on-board vs. off-board charging, weighing cost vs. performance considering the tradeoffs of each and focusing on an established partner-supplier. The don’ts consisted of don’t electrify for the sake of electrification, don’t design in a silo, don’t design around one component, don’t select a charger that doesn’t “work”, always look for a charging solution based on the environment, don’t assume that performance outweighs cost and don’t treat components as a commodity.

A smaller company’s perspective towards overcoming the challenges of decarbonization projects

John Westman, Engineering Manager at Pettibone/Traverse Lift, LLC

John explained the unique challenges of being a small company manufacturing equipment aimed at decarbonisation. Unique challenges included development costs, regulatory compliance,  safety investment,  battery end-of-life considerations and utilising limited resources. The advantages of being a smaller company included a flat organizational structure, the ability to leverage what works,  adaptability & customization, mitigating customer risk and having resource expertise development.

Electrify Linear Actuators for Heavy Equipment

Jack Wang, President of Zoomlion Heavy Industry NA

Jack compared the similarities between the dynamic systems of hydraulic excavators to the human muscular anatomy, how the controller and electrics are much like the brain and nerves with the engine and powertrain acting and the heart and blood, hydraulics the muscle and the structure itself acting as the skeleton. He introduced several electrified excavator concepts and the challenges of the use of linear actuators instead of hydraulics in these vehicles. He explained and compared hydraulic circuits for linear cylinders, hydraulic cylinders, electrical linear actuators, electric motors and linear motions and their potential applications in off-highway vehicles.

Faster than Realtime Power Converter & Motor Drive System Simulations with Trained Physics Models for System Cost Optimization

Albert Dunford, Director Global Technical Team at Altair Engineering

Albert discussed how to balance efficiency and weight or longer run times and larger ranges, with the ultimate objective being to reduce cost. Efficiency gains can be found in inverter design by choices in device selection, inverter operating temperature, gate drive impacts and control decisions. By using a motor drive fit model for system simulation and inserting data from DC bus voltage, torque command, motor shaft speed and inverter temp which the model analyses with a therm inverter model, a FLUX reduced FEA motor and control algorithm, the fit model provides actual developed torque, losses from the inverter and losses from the motor.  Altair ToolChain fit model uses power electronic design and simulation environment coupled to HyperStudy to train the algorithm for the system simulation. Albert spoke about adaptive gate drives allowing for weak gate drive to be used at high SOC and strong gate drive used at lower SOC.

How and why do off-road worksites need to evolve for sustainable power?

Dr. Ray Gallant, Vice President of Sustainability and Productivity Services at Volvo CE

The steps to sustainable power start with selecting the right machine technology (battery electric, grid, or H2), the system used to charge or refuel this vehicle, running energy efficient worksites and prioritising energy management. Dr Gallant then recapped the demo use of the EC230 which has its total carbon intensity offset after approximately 4,400 hours of operation when accounting for the carbon footprint produced from cradle to gate.  Its total fuel saving was $2,138, making it 82% more cost effective. The vehicle decreased its energy cost by 70%, operator cost by 40% and its CO2 output by 95%.

Scaling Axial Flux Motor Technology – From Niche to Mainstream

Matrishvan Raval, Head of Product at Turntide Technologies

Matrishvan started his presentation by introducing the Axial Flux motor, where the magnetic flux direction is parallel to the axis of rotation.  Turntide Axial Flux motors are 2 to 4 times more torque dense than the standard radial flux motors – resulting in 50% weight and volume savings for the powertrain. Axial Flux technology enables high power and torque in a very thin design making it the primary motor technology for high performance or space-critical applications. He concluded that Axial Flux motors are an inherently superior technology offering higher performance leading to smaller, lighter, higher efficiency, and more powerful motors.

Zero Emissions Off-Highway Heavy Machinery Design Using Beltdraulics™

Hiten Sonpal, CEO of RISE Robotics

Hiten gave his solution to the electrification of heavy machinery being unviable due to hydraulics with Beltdraulics™. Screw type actuators have limitations such as shock loading, maximum length and speed but Beltdraulics™ offer hydraulics that are 3X faster, 3X more efficient and up to 20% lighter. The use of belts instead of hydraulic oil or screws regenerates energy on the way down, making it shock-load ready and able to deal with up to 400 kN force per cylinder. Beltdraulics™ offer zero unplanned downtime, are autonomy-and IoT-ready, are able to be used indoors and outdoors and are silent.  

Day Two

Hydraulic control systems for battery operated vehicles

Andrea Vacca, Maha Fluid Power Faculty Chair at Purdue University,

He started with a brief introduction of the Maha Institute and its history and a review of the current technological capabilities of off-road vehicles. Future technology being developed for off-road vehicles should consider a focus on damping/resistance to shock, cooling arrangement, energy efficiency,  productivity and battery requirements. Andrea discussed fluid power vs. electromechanical actuation,  analysing its cost, energy efficiency, productivity and cooling arrangement, space claim and noise/vibration. He then discussed e-pump design and their speed requirement, pressure requirement,  hydraulic fluid, materials, finishing and industrialization. He also talked about multics and fluid displacement, lubricating gap power loss, moving part micro-motion, material pressure deformation, asperity contact / mixed lubrication and cavitation. He concluded that sustainable off-road vehicles and cleaner prime mover technologies require more efficient actuation system actuation technologies,  hydraulic actuation has distinctive advantages over electromechanical ones and there are opportunities to redesign hydraulic control systems.

Modernizing a “Dinosaur” for the 21st Century

Stephen M. Speakes, President and CEO of the Independent Rough Terrain Centre (IRTC) LLC

Stephen started his presentation by discussing the Rough Terrain Container Handler (RTCH): obsolescence due to its use of an 11 litre engine and transmission impacting the fuel consumption and performance. They chose to make the vehicle hybrid electric, using an Electric Variable Transmission (EVT) which provides more instantaneous responses and reduces the need for multiple operator inputs. Only one footpedal is needed to control engine rpm, acceleration, and braking, making it easier for operators. Running the RTCH at a constant RPM means that operators can realize constant hydraulic response when needed without having to adjust when operating, with estimated fuel savings will averaging 30% from current V4 solution. The vehicle performance is smoother and provides more load stability and the RTCH becomes an energy provider with the ability to off-load up to 200kW of power.

A research and innovation partner’s approach for AM supporting electrification

Ellen Scott, Senior Researcher – Energy Conversion at RISE Research Institutes of Sweden

Ellen introduced the RISE mission for a fossil-free vehicle fleet by working with customers and partners to develop competitive solutions that drive sustainable development forward. She then explained the testing value chain that RISE offers that checks material, components, complete vehicle, and the system with verification, certification and validation. She also touched upon zero-emission off-highway projects in Sweden such as the first fuel cell electric Articulated Hauler, utilising a modular battery swap system that can serve the agricultural and forestry sectors. RISE offers a world-unique and sustainable indoor lab for battery testing and Battery Management System research as well as RISE AstaZero which is a world-leading test environment for the automated transport system.

Off-Highway Low Emission Retrofit Impact

Ilmars Nartish, Vice President North America at Manitou Group, 

Ilmars discussed their partnership with Kiloutou and the first retrofit telehandler, the MT1440 a 2017 model with 2500h that was used for rental 80% of the time. After retrofitting, specifications were the same as initial characteristics but it now had operating autonomy for a day, could be fully charged in under 9 hours and vehicle lifespan was extended by 5 years or 2500 hours. Ilmars also discussed how the  “ecological break-even point” of the retrofit operation is located at approximately 40% of the theoretical duration of use, or 4,000 hours (for an end-of-life at 10,000 hours). A retrofit improves the environmental performance of a machine and leads to a reduction of GHG emissions by 30% to 50% (depending on modelling assumptions) with transfers of impacts to other environmental indicators. The extension of machine life linked to the retrofit should generate an additional environmental benefit.

The Dutch Approach To Clean And Emission Free Construction-Equipment

Peter van Schaik, Program Manager for Clean and Zero-Emission Construction, and Dik de Weger, Programme Manager Emission Free Construction Equipment, at Rijkswaterstaat

Peter and Dik began their presentation by recapping developments in the Netherlands such as the National Covenant Clean and Emission Free Construction drives, subsidy schemes and additional project budgets with investments by all large building companies and small and medium enterprises amongst the front runners. Machine manufacturers in the Netherlands are focusing on conversion and retrofit in cooperation with large OEMs and a road map of charging facilities for the construction sector is being organised. Dutch zero-emission projects include the RWS Road Construction Projects of several highways using electric equipment and use of energy from adjacent companies.  RWS Road Maintenance Projects utilises a full electric Asphalt Recycling Train and there are municipality initiatives across the country to provide charging facilities for road reconstruction projects. The Dike Reinforcement Programme is a carbon-neutral hub dedicated to powering electric construction equipment and trucks with renewable energy sources.

Emission Reduction Strategies for the Off Road in California

Bill Robertson, Vehicle Program Specialist at CARB

At the start of his presentation, Bill stated that 70% of Californians still breathe unhealthy air. By using 100% renewable diesel greenhouse gas emissions with incremental NOx & PM is released. With the quantum expansion of the scope of zero-emissions regulations new jobsites can be unlocked, a variety of applications, and tasks with formerly prohibitive demands. Bill shared incentive projects such as the CARB Incentive Program, FARMER Incentive Program and Vouchers for Commercialized ZE Equipment. Bill also shared upcoming regulatory actions such as the Phased Advanced Clean Equipment and Tier 5 Engine Standards Rulemaking.

An Innovative Solution to address thermal management issues for electrified off-highway machinery

Panos Prezos, Commercialization Lead at Calogy Solutions

Panos shared the obstacles to electric heavy machinery vehicle adoption such as range/run-time, total cost of ownership, safety, high power requirements, harsh environments and charging infrastructure. He shared Calogy’s Uni.T ™ Thermal Solution which offers a longer product lifetime by lowering average cell temperature by 10°C can double life expectancy, as well as being easy to integrate and low cost. He also talked through their L.PACK™ Battery System solution that maximises a cell’s power capability by optimising thermal management, enabling more useable energy at high power, getting the vehicle or instrument back to work, cycle after cycle

Ballast Nedam Sustainability

Jeffrey Hoffman, Director of Ballast Nedam Equipment BV at Ballast Nedam NV

Dutch companies are uniting, forming an ecosystem of front runners from throughout the whole value chain and working to realise a zero-emission construction site by 2026 in the infrastructure market. They are focused on heavy-duty machines >125kW and improving energy efficiency,  production efficiency, fleet efficiency, financial efficiency, and new cost drivers. Zero emission construction can be achieved by the use of electric machines, integration of charging infrastructure and energy logistics, utilising methods, planning and design for zero emissions, considering energy transition on- & off-site, implementation of new discipline and rules and use of data and monitoring.

Exhibitors

The DZOMUSA was supported by a wide range of companies who brought their teams to our exhibition hall and Innovatrix would like to thank them again for their support:

Alfagomma, Algoryx, Altair, Axiomatic Technologies, Calogy, Canimex, CoreM2M, DISTek, Dukosi, EVONOMY, EVR Motors, Hengli, IST AG, Joral, Mach, Motec, Opal-RT Technologies, Owasys, Oxford Technical Solutions, Pratt Miller, Purdue University, RISE Research Institutes of Sweden, RISE Robotics, Rota, smartmicro, technotrans, Tier IV, tracetronic, Trelleborg, Turntide and Zapi Group

If you want to attend our next zero emissions off-highway summit and have the opportunity to hear presentations like these and many more, join us for our European edition this May. To discover the latest innovations and trends in electrifying off-highway machines, meet with solution providers and hear talks from industry leaders, attend the 6th Design and Development of Zero-emissions Off-highway Machinery Summit taking place in Berlin, Germany on May 21-22, 2025.

For more information, visit our website or email us at info@innovatrix.eu for the event agenda. Visit our LinkedIn to stay up to date on our latest speaker announcements and event news.