System integration is pivotal in electrifying non-road mobile machinery (NRMM). In the recent webinar, Powering Progress: Innovations in Charging Solutions for Off-Highway Mobile Machinery, Rod Dayrit, Global Director of Business Development, Charging Solutions, led an insightful discussion on the trade-offs of such integrated solutions.
While the industry continues trending towards holistic drivetrains, OEM design teams must carefully weigh the benefits against the challenges of implementing these systems. According to Dayrit, an ideal balance exists between the cost-efficiency of integrated systems and the flexibility of modular designs.
As highlighted below, the insights discussed in the webinar offer a comprehensive blueprint for OEMs seeking to electrify—identifying vital considerations for developing efficiently integrated solutions.
Defining Integrated Solutions in Industrial Electrification
“Integration” refers to systems in which multiple components are designed to function seamlessly within a unified architecture. In the context of charging solutions, a fully integrated system might encapsulate key components, including:
- On-board chargers
- AC export power
- DC-DC converters
- Electric vehicle supply equipment (EVSE) interfaces
This approach contrasts with discrete systems, where each component operates independently and requires manual interconnection.
Why Integration Matters
For electrified NRMM, integrated systems represent the industry’s ideal solution. By leveraging advancements in communication protocols and component design, integrated systems achieve synergistic benefits otherwise unattainable in standard combustion machinery. Electrified NRMM operating on an integrated platform exemplifies improved efficiency and cost-effectiveness, all in a more compact package.
Analyzing the Trade-Offs: Flexibility vs. Cost-Effectiveness
Despite the advantages, integration may impose unintended limitations. The primary trade-offs can be summarized by comparing:
- Flexibility – Integrated systems can be less adaptable. Upgrading a single component often necessitates redesigning interconnected elements, increasing downtime and costs compared to modular, discrete systems.
- Cost-effectiveness – Integrated solutions reduce production costs and shift development risks to suppliers, generally lowering the cost of initial investments. In contrast, discrete systems demand greater upfront integration efforts since OEMs must source components from parallel markets.
These trade-offs are not new. Lessons from mature markets demonstrate that electrified products naturally trend toward integrated solutions. OEMs leveraging such cross-industry insights position themselves to strike the ideal balance for their unique vertical and application.
Example Case Studies in Critical Applications
While trade-offs exist, certain components require integration. This is particularly true for chargers—the critical interface between internal systems and external infrastructure.
Consider the following three examples that further illustrate this point.
Example #1: Upgrading On-Board Chargers
Consider an OEM seeking to upgrade an electric drivetrain to accommodate a higher DC-DC power load. In a traditional setup with discrete components, this is straightforward: the OEM can simply replace the charger with a more powerful unit.
However, an integrated design proves more challenging since each component interconnects as a single system. While these integrated, packaged solutions are initially more cost-effective, their inherent rigidity can complicate component-level upgrades and repairs.
Example #2: Ensuring EVSE Compatibility
EVSE systems rely on complex communication protocols to ensure safe and efficient power delivery. Unlike refueling a combustion vehicle, recharging electrified machinery requires precise coordination to manage:
- Safety protocols – Real-time monitoring of power flow ensures systems can prevent overloading, overheating, and short-circuiting.
- Global charging standards – Adherence to protocols such as the J1772 ensures interoperability across vehicles and charging stations worldwide.
In this scenario, integration is non-negotiable if OEMs intend to leverage EVSE charging.
Off-road machinery must pair with an electric vehicle communication controller (EVCC), which governs the “handshake” between charging infrastructure and the vehicle’s on-board systems.
Since this component is central to a secure and standardized charging experience, almost every machine benefits from having a built-in EVCC versus a discrete one. The benefits compound when OEMs can delegate integration to component suppliers—capturing the advantages of an integrated system while mitigating associated complexity and cost.
Example #3: Digitalized Fleet Management
Real-time data exchange between vehicles, chargers, and cloud-based platforms is also made possible through integrated solutions. Often built into an intelligent battery management system (BMS), these communications enable advanced features such as:
- Improved diagnostics that detect and address issues before they escalate—from monitoring battery health to identifying potential abuse or malfunctions.
- Optimized charging schedules that reduce downtime and improve fleet utilization by matching charging algorithms to vehicle usage.
- Intelligent workflows designed to spread battery use evenly across the fleet, enabling predictable maintenance schedules and extending battery life.
Again, integration is a key factor in unlocking these benefits. While discrete components may be easier to maintain and replace, OEMs must weigh the trade-offs of “flying blind”—without the valuable insights provided by integrated systems.
Consulting with System Integrators for a Balanced Solution
To navigate the complexities—and unlock the benefits—of electrification, OEMs require strategic partnerships with experienced system integrators. The right electrification partners bring expertise in developing solutions that combine the best aspects of integration and modularity, enabling OEMs to:
- Reduce development risks by delegating integration to suppliers and third parties
- Future-proof designs to accommodate emerging standards and innovations
- Ensure component compatibility and optimization across diverse systems
As Dayrit noted in the webinar, the ZAPI GROUP of companies exemplifies the value of such partnerships.
With over four decades of experience in electrification and a global network of suppliers, ZAPI GROUP delivers tailored, integrated solutions designed to meet the specific requirements of industrial and off-highway applications.
ZAPI GROUP: Powering a Fully Integrated Future
As industries continue to embrace electrification, the importance of strategically integrated solutions will only grow. While integration offers undeniable benefits, OEMs must carefully navigate trade-offs between flexibility and cost-effectiveness to create sustainable, future-ready systems.
Partnering with trusted system integrators allows OEM development teams to strike this balance, drawing on these partnerships for the expertise and cross-industry insights needed to fuel competitively designed solutions.
ZAPI GROUP, recognized for extensive expertise and multi-industry OEM support, is uniquely positioned to meet the evolving needs of the industrial electrification market. Under the Delta-Q Technologies and ZIVAN product brands, ZAPI GROUP delivers charging solutions from 350 W to 36 kW designed for easy integration with their other solutions and their battery partner network.
Watch the full webinar to learn more, or contact ZAPI GROUP for more information on how our solutions can power progress in your electrification journey.