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.
“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:
This approach contrasts with discrete systems, where each component operates independently and requires manual interconnection.
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.
Despite the advantages, integration may impose unintended limitations. The primary trade-offs can be summarized by comparing:
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.
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.
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.
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:
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.
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:
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.
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:
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.
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.