The path to off-highway electrification – electric heavy equipment vs on-road EVs

Patrick Zenker
​

Patrick Zenker is Head of Innovation & Digital at Trelleborg with hands-on experience in developing digital systems and solutions for AVS. He has led on groundbreaking ‘smart product’ projects, including the development of the ConeX3

---

Until recently, passenger vehicles have dominated conversations and regulatory requirements when it comes to electrification. Now, industries reliant on heavy machinery are undergoing their own transformation. In this article, Patrick Zenker from Trelleborg explains why, for off-highway EV manufacturers, it’s not as simple as copying and pasting our learnings from the automotive industry.

While the development and adoption of on-road electric vehicles (EVs) has been a big global effort, we have seen a relatively smooth transition with ever-increasing demand. The electrification of heavy equipment has been a slower process and presents unique engineering challenges.

So what have we learned from on-road EVs that can be applied to this field of innovation, and how do off-highway vehicles differ?

Designing electric heavy equipment – a unique challenge

Lithium-ion batteries, cooling systems, torque control, optimizations via integrated software and energy management systems have all vastly improved in the race to develop competitive on-road EV technology. This, in turn, has helped manufacturers accelerate towards game-changing off-highway solutions. But developing these machines will present its own engineering challenges.

Off-highway vehicles operate in demanding environments where uptime, power output and durability are critical. Unlike on-road EVs, which benefit from established charging networks and predictable routes, electric heavy equipment must function reliably in remote locations for a wide range of applications in a variety of working conditions. So, what are the key differences when it comes to on-road vs. off-road vehicle electrification?

Battery integration, size and power density

Electric heavy equipment requires significantly larger battery capacities than passenger EVs due to their energy-intensive operations. Whereas an electric car’s battery pack typically ranges from around 30-100 kWh, a piece of construction equipment, such as an electric excavator or wheel loader, may need battery packs of 180-400 kWh (in some cases even as high as 700 kWh). The integration of these high-capacity batteries must balance power density with weight distribution and take dynamic load and vibrations into consideration.

Thermal management also becomes more complex. Off-highway environments expose batteries to high vibration levels, extreme temperatures, and dust or debris infiltration, necessitating advanced cooling systems and protective enclosures to prevent overheating and damage.

Electric off-highway vehicle manufacturers are using and developing vastly different battery configurations, so there is no one-size-fits-all solution – we’re yet to fully understand how long-term total cost of ownership will be impacted by the transition. While some construction EVs already include antivibration solutions within their battery packs, other manufacturers opt for a more traditional setup, in which the additional mounts will provide essential isolation from the vehicle’s structure.

Charging infrastructure and time between charges

Unlike on-road EVs that can access fast-charging networks, electric heavy machinery often operates in remote job sites where charging infrastructure is limited or non-existent. This makes charging logistics a significant hurdle for vehicle-fleet electrification in construction and mining applications.

Some solutions being developed and explored include:

• Battery swap systems – these allow quick replacement of depleted batteries, minimizing downtime.
• Fast on-site charging high-voltage DC fast chargers designed for industrial applications can recharge large battery packs in hours instead of overnight. Some mining sites are using locally produced energy from EV panels to charge their machinery. –
• Hybrid options
  
  – some manufacturers are exploring diesel-electric hybrid models to extend operational hours without full dependence on charging infrastructure

Differing measures of performance

While the on-road EV’s primary function is to get people or goods from A to B, off-highway vehicles can serve a diverse range of roles and requirements. Electric heavy equipment must therefore meet different performance demands, making the move to 100% electric power sources more challenging.

According to Dr. Wilfried Aulbur, Senior Partner at Roland Berger, compact vehicles such as mini excavators are the ideal use case for EVs because they require less power density variations in their duty cycle. He recommends hybrid technology for larger, heavy-duty applications due to their operating cost benefits as well as performance stability, with some OEMs claiming to reduce fuel consumption by more than 25%.

But that doesn’t mean there aren’t high-performing fully electric options. With a number of manufacturers investing in their development, it’s just a matter of time before these heavy-duty EVs can match hybrid vehicles.

Thriving in extreme environments  

Also vital to the performance of off-highway equipment is its ability to endure extreme environments – whether it’s sub-zero temperatures in construction zones in northern markets or the intense heat of mining operations.

This poses unique challenges for battery-powered equipment. For example, unlike internal combustion engines (ICEs), which generate waste heat that can warm hydraulic fluids and cabin interiors, electric powertrains require supplemental heating systems in cold climates.

vibration is still a key consideration Additionally,  [RM1]
when it comes to vehicle fleet electrification, due to functional similarities between off-highway ICEs and EVs (delivery of torque at low operating speeds).

Electric vehicles also have numerous components that are more fragile and valuable than in traditional ICE-powered machines. From battery packs and motors to sensors and radars, the risk of damage to these valuable assets makes anti-vibration solutions a must.  

Operator comfort and safety

A less-discussed but crucial advantage of electrification in off-highway applications is improved driver comfort, which has a direct impact on-site safety. Vibration and noise are common sources of discomfort that add risk to off-highway vehicle operation. The transition to electric batteries is a valuable opportunity to get ahead of this challenge and include anti-vibration solutions as standard.

With strategically positioned rubber mounts, electric heavy machinery produces significantly lower vibration and noise levels than diesel-powered counterparts, reducing operator fatigue over long shifts.

Equally, the absence of exhaust emissions improves air quality, making construction sites safer and reducing their impact on the environment.

The path to off-highway electrification

As regulatory pressures for emissions reduction intensify and the cost of renewable energy continues to fall, the push toward electric heavy equipment is accelerating. Companies investing in electrified heavy machinery must navigate the challenges of infrastructure development, battery performance and operational logistics. However, the benefits – reduced emissions, lower operating costs and improved worksite conditions – make it an inevitable transition.

The electrification of heavy machinery and widespread EV adoption is no longer a question of ‘if’ but ‘how fast’. As technology advances, industries like construction, mining and agriculture must focus on making zero-emissions sites a reality, working with manufacturers to ensure machines meet the high-performance standards required in the field.

Future-proof engineering

While on-road EVs have set the precedent, the path to off-highway vehicle electrification requires engineering ingenuity tailored to unique demands and specific use cases.

Trelleborg’s specialists combine in-depth knowledge of off-highway vehicles and anti-vibration expertise to support a wide range of engineering challenges and electrification opportunities.