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ICE Hybrid drive system

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Customer challenge

The off-highway industry is transitioning towards electrification to meet stringent emission regulations, improve energy efficiency, and reduce operational costs. However, for high-power machines or applications with intensive daily use, full battery electric vehicles can be challenging or even impossible to implement due to energy storage and charging constraints. In such cases, hybridization presents a more viable solution, combining the benefits of electrification with the reliability of internal combustion engines. But, transitioning to hybrid powertrains presents several challenges:

  • Integration complexity – Adding an electric power source alongside an internal combustion engine requires precise coordination of multiple components.
  • Electrical and mechanical adaptation – Proper mounting, cooling, and connection of the generator, inverter, and battery system must be carefully designed.
  • Hybrid power management – Efficiently balancing power distribution between the engine and electric system to optimize performance and energy savings.
  • Development time and cost reduction – Minimizing engineering efforts and ensuring fast deployment without compromising reliability.

System description

Our ICE Hybridization Kits provide a modular and scalable solution to upgrade off-highway machines with hybrid capabilities. Each kit includes:

  • Generator & mechanical adaptations – A high-efficiency generator mounted to the engine to convert mechanical energy into electrical power.
  • Inverter – Converts and regulates the electrical energy for optimal system operation.
  • Hybridization battery pack – High-power battery system featuring high C-rating in order to support peak power demands, enabling effective peak shaving and ensuring optimal energy distribution during operation.
  • PM-ECU (Power Management ECU) – An intelligent controller with pre-validated hybrid management software, ensuring smooth energy distribution and seamless operation.

These components are pre-engineered for compatibility, allowing for easier integration into existing vehicle architectures while maximizing fuel efficiency and reducing emissions.

System diagram

Typical applications

Pictogramme construction

Construction equipment

Picto Agriculture

Agriculture

Picto Material Handling

Material handling

Picto Airport GSE

Airport GSE, Municipal & Special vehicles

Customer benefits & System features

1

Improved fuel efficiency

Reduced engine load and optimized energy use lower fuel consumption.

2

Lower emissions

Hybrid operations minimize CO₂ and pollutant emissions.

3

Plug-and-Play integration

Pre-configured components simplify system implementation.

4

Robust & durable

Designed for demanding off-highway conditions with advanced thermal management.

5

Advanced energy management

Intelligent control strategies optimize power split between the engine and electric system for maximum efficiency.

6

Safety ready

The PM-ECU features a pre-validated control software, ensuring functional safety
compliance and application-specific configurability.

7

Peak power support

High-C-rating batteries efficiently handle power peaks, reducing strain on the engine and improving performance.

8

Downsizing opportunities

Hybridization allows for downsizing in the selection of the diesel engine power, potentially under the thresholds that require costly and space-consuming after-treatment systems.

Technical features & data

Engine SAE interface

  • SAE 5 – 6,5″
    to
    SAE 0 – 14″

Generator power

  • 10 to 500 kW

Voltage

  • 48V to 800V

Cooling

  • Air & Liquid Cooling

Communication protocols

  • CAN, CANopen, J1939

Hybridization battery C-Rating

  • Continuous: 2 to 5°C
  • Peak: 3 to 9°C

Parallel hybrid options

  • Via multi-inputs/outputs gearbox
  • Via through-going generator shaft
  • Diesel-engine de-clutching option