OEM Charger Selection: 3 Design Considerations for Efficient Electrification

When electrifying industrial machinery, battery and charger selection often fall to the final stages of development. However, these choices rank among the most critical in driving system efficiency and optimizing performance for specific applications.

Achieving these outcomes starts with a forward-thinking approach during the design phase. 

The recent ZAPI GROUP webinar, “Mid-Power Charging Solution Options for Non-Road Mobile Machinery (NRMM)”, explores three essential design considerations, highlighting the value of scalable, versatile charging technologies in OEM electrification projects. 

Equipped with the right charging solution—and the expertise to integrate it into the surrounding vehicle architecture—OEMs position themselves to deliver reliable, cost-efficient machinery tailored to their unique vertical.

Consideration #1 - Functional Parameters: Meeting the Application’s Core Requirements 

The foundation of every electrification project, functional parameters represent the hard numbers and logistical considerations underpinning OEM designs. 

These parameters include: 

• Battery compatibility – For chargers to deliver power safely and effectively, it must be optimized to the specific battery. Choice of battery chemistry, for instance, directly influences which algorithms the charger uses to maximize battery life—protecting this significant investment and enhancing ROI.
• Nominal voltages – NRMM often operates at lower voltages, requiring mid-power charging solutions that align with industry and machinery standards. Such platforms cannot benefit from publicly available EV fast-charging stations due to compatibility issues, further highlighting the necessity of bespoke charging solutions. 
• Charge speed and power – Charging profiles balance energy replenishment without compromising long-term battery performance. Tailored solutions meet operational needs while mitigating the long recharge times often associated with non-optimal chargers.
• Infrastructure power source – Only the charger is capable of negotiating the grid-to-machine power transfer, requiring unique connectors depending on whether that connection is industrial, residential, or portable. 
• Thermal management – Effective cooling is the responsibility of both the charger and the overall vehicle design. Particularly for on-board charging solutions, where the charger is located, and how it achieves cooling (e.g., liquid, fan, or hybrid systems) require careful consideration.

OEMs must approach functional design by evaluating more than just individual components, but how these components will interact and optimize one another—the machinery’s entire ecosystem. 

Rather than simply fulfilling the vehicle’s basic requirements, electrification promises to boost equipment efficiency to new levels, leveraging synergistic technology such as regenerative braking. The interconnected nature of such innovations demands a holistic design approach.

Consideration #2 - Non-Functional Parameters: Guaranteeing Long-Term Performance

While no less important, non-functional parameters represent the more “conceptual” aspects of the design phase. Such considerations include: 

• Level of customization – From discrete, off-the-shelf components to fully original designs, OEMs will need to decide which electrified subsystems see integration and customization, and to what degree.
• Ruggedness and durability – NRMM and industrial machinery must withstand extreme temperatures, vibrations, dust, moisture, and similar hazards. Ensuring the charging solution itself is capable of consistent operation across environments is crucial.
• Reliability – Aside from sourcing high-quality components, reliable charging solutions minimize downtime and maintenance costs—essential for customer satisfaction and ROI.
• EMC/EMI compliance – Effective shielding reduces electromagnetic interference, ensuring compatibility with other electronic systems.
• Regulatory compliance – Global emissions, efficiency, and safety standards continue to tighten. High-quality chargers should adhere to, even future-proof against, regulations across international markets.

With these challenges in mind, reliable charging solutions—backed by customization and integration expertise—emerge as the natural choice for OEMs.

Consideration #3 - Choice of Component Supplier: The Right Partner for Electrification

OEMs need holistic, comprehensive solutions providers that can handle integration and optimization.

Electrification projects often require design decisions that extend beyond the immediate scope of the machine. Beyond simply providing parts, the ideal supplier therefore serves as a strategic partner; they deliver the expertise needed to reduce design team burden and accelerate development cycles. 

By involving suppliers early in the workflow, OEMs can:

• Accelerate time-to-market, leveraging the supplier’s cross-industry insights to streamline integration for optimal performance
• Address compatibility challenges from the conceptual design stage, sidestepping costly redesigns 
• Ensure quality and reliability by tapping into the supplier’s strong legacy of component dependability and electrification expertise

By aligning with a comprehensive electrification partner, OEMs can deliver cutting-edge solutions that redefine efficiency and performance in their industries.

 The ZAPI GROUP Approach: Specialized Solutions for OEM Applications

With 50 years of experience in industrial electrification, the ZAPI GROUP of companies is a top choice for global OEMs seeking to electrify. 

Our expertise in system integration and multi-industry OEM support carries through to each battery charging solution in the ZAPI GROUP product portfolio, including:

• On-board chargers – The Delta-Q XV3300 and ZIVAN CT3.3 enable full machine integration to maximize efficiency across the drivetrain. Compatible with J1939 charging standards and offering intuitive user interfaces that display recharge state and charge cycle info, both solutions enable efficient electrical designs with a compact footprint.
• Off-board “portable” chargers – The newly-released ZIVAN SG9 closes a critical market gap by means of a mobile, 9kW charging solution. With IP-rated protection, ruggedized wheels and handles, and compatibility across residential and industrial charging infrastructure, the SG9 ensures easy-to-deploy and efficient charging across entire fleets. 
• Stationary chargers – While not offering standalone stationary charging equipment, ZAPI GROUP delivers expertise in consulting with OEMs on advisable solutions for their vertical. These recommendations come from an in-depth analysis of the OEM’s charge and discharge cycles, load weight and size, and floor layout—all in relation to machine duty cycles. 

Quality products combined with a systems-integration context allow ZAPI GROUP to match OEM needs with a charging solution tailored to the machinery and the application.

Full Integration and Expertise: ZAPI GROUP’s Speciality 

Today’s OEMs face mounting pressure from multiple angles—the need to reduce carbon footprints, develop efficient electric drivetrains, and manage the total cost of ownership. 

Amidst these challenges, battery chargers may seem like a secondary consideration. 

However, the reality is that charging solutions are often the key to addressing these (and many more) challenges. The right electrification partner relieves OEMs of the developmental burden associated with such solutions, providing access to tailored charging technologies along with the expertise to efficiently integrate them.

From meeting sustainability targets to accelerating time-to-market, ZAPI GROUP provides the strategic partnership OEMs need to stay competitive.

Watch the webinar to learn more, or connect with a ZAPI GROUP expert to discover the charging solution best suited to your unique needs.