eTransformer:

Electric retrofit of MAN TGX/TGS with optimized integration

The challenge

Electrifying heavy trucks without compromising functionality

The electrification of heavy-duty trucks presents a significant challenge: replacing the internal combustion engine without affecting essential functionalities, particularly compatibility with onboard equipment and the drivetrain.

Kinell has developed retroDRIVE, a retrofit solution designed to integrate an electric powertrain into MAN TGX/TGS trucks. The goal: ensure an efficient energy transition while preserving key mechanical interfaces (PTOs, gearbox, OMSI) and maintaining compatibility with existing superstructures.

The solution

retroDRIVE: A fully integrated and optimized electric conversion

The retroDRIVE system, developed as part of the AGGREGATE project by Kinell, is based on three interdependent subsystems:

1. eAggregate: replacing the diesel engine with an electric powertrain

Direct integration of an electric motor replacing the MAN D26 Diesel engine without structural modifications.
Retention of original auxiliaries (servo pump, air-conditioning compressor) to minimize adaptations and ensure compatibility with standard maintenance.
Development of an advanced control system, replacing the diesel ECU while replicating original interactions with other subsystems.

2. Battery system: high-capacity energy storage and chassis adaptation

Integration of high-energy-density batteries replacing the diesel tank and AdBlue system.
Optimized sizing to meet autonomy constraints and power demands of onboard equipment (off-road applications, high energy consumption).
Reinforced protection and advanced thermal management to maximize battery durability in extreme conditions.

3. Charging and distribution system: intelligent energy management

High-power distribution and interface unit, installed in the filter compartment for minimal space impact.
Fast-charging capability and optimized energy distribution between the motor and auxiliaries.
Compatibility with high-power charging standards, ensuring seamless integration with existing charging infrastructure.

The outcome

A turnkey solution for energy transition

Retrofit without altering the original architecture: The truck’s original design is maintained for seamless and robust integration.
Operational continuity and simplified maintenance: Conventional mechanical equipment (PTO, OMSI) remains fully functional without modifications. Original auxiliary components are retained, ensuring full compatibility with MAN’s existing maintenance services.

With retroDRIVE, Kinell delivers a pragmatic and robust approach to electric retrofitting, enabling a smooth transition to electromobility without sacrificing performance or operational reliability.

Let’s get in touch and explore how we can collaborate!

You are working for an OEM ? You need expertise in design and integration of engineering systems ? At Kinell, we are committed to being your trusted partner in bringing your most ambitious projects to life.