Electrification is transforming the industrial equipment landscape, but for OEMs, one critical decision stands out: should they choose a fully integrated powertrain system or handpick individual components?
In a recent session, Kai Schlüter, Sales Engineer at Jungheinrich Powertrain Solutions, shared his expertise on this pivotal choice, drawing on Jungheinrich’s decades of experience and a global fleet of over one million electric forklift trucks.
Understand the Powertrain Integration Challenge
At the heart of every electric machine lies the powertrain: a system of battery, charger, inverter, and electric motor(s) that must work together seamlessly. Electrification isn’t just about replacing an engine with a battery; it’s about ensuring these components communicate and operate reliably under real-world conditions. The integration approach—fully integrated or handpicked—will impact engineering workload, time to market, and long-term support requirements.
- Fully Integrated Systems: All components are sourced from one supplier, designed to work together, and managed by a unified controller.
- Handpicked Components: Select each part—battery, inverter, charger, motor—from different suppliers, tailoring the system to specific requirements.
Break Down the Core Components and Interfaces
A modern electric powertrain consists of four main components:
- Battery
- Charger
- Inverter
- Electric Motor(s).
Each element interacts through several critical interfaces:
- CAN Communication: Transmits essential data—state of charge, error codes, torque requests, and more.
- Electrical Interfaces: Handles high-voltage DC and AC connections, plus signal lines for control and safety.
- Signal Interfaces: Manages functions like battery wake-up and charger detection.
These interfaces are complex. For example, the inverter must always respect the battery’s allowed charge and discharge currents, especially during regeneration. Failing to do so can trigger protective shutdowns, causing unexpected machine behavior. Pre-charging inverter capacitors before closing contactors is crucial to avoid hardware damage. Managing regeneration current, particularly when the battery is full, requires system-level coordination—sometimes activating alternative braking to avoid overcharging.
Evaluate Handpicked Solutions: Flexibility Meets Responsibility
Handpicking components allows the freedom to optimize every aspect of the machine. Select from a best-in-class battery, the most efficient inverter, or a motor that fits a unique form factor. This approach is especially valuable for niche applications or when you need to maintain legacy mechanical designs.
But with flexibility comes responsibility. The requirements are to:
- Ensure all components communicate reliably, especially across CAN and electrical interfaces.
- Manage system-level safety, including pre-charging inverter capacitors and handling regeneration currents.
- Troubleshoot integration issues, often without clear support from suppliers.
- Resolve warranty claims when multiple vendors are involved.
Anecdotally, many OEMs new to electrification underestimate the time and expertise required to make disparate components work together. The result can be extended development cycles and increased risk of field failures.
Leverage Fully Integrated Systems: Streamline Development and Support
Fully integrated powertrain systems offer a different set of advantages. By sourcing all components from a single supplier, the resulting solution is designed, tested, and validated as a complete package. This approach:
- Reduces integration workload and accelerates time to market.
- Minimizes the risk of interface issues and system-level failures.
- Provides a single point of contact for technical support and warranty claims.
However, integrated systems are often standardized, which may limit options for customization or require mechanical adaptations to fit existing designs. Still, for most mainstream applications, these systems deliver reliable performance with less engineering overhead.
Jungheinrich Powertrain Solutions, for example, has supported the electrification of over a million forklifts worldwide. Their experience shows that most OEMs can achieve their goals with standard integrated components, reserving handpicking for highly specialized projects.
Focus Project Risk on Strengths
The key to a successful electrification project is to focus risk where the team has the most expertise. If strongest in mechanical engineering, consider adapting the designs to accommodate integrated powertrain modules. This lets the team manage risk in familiar territory while leveraging proven electrical systems. More experience leads to more customized approaches in future projects.
Apply Best Practices for Powertrain Integration
To ensure a smooth electrification process, keep these best practices in mind:
- Document All Interfaces: Use interface control documents (ICDs) to map out electrical, communication, and signal connections.
- Validate System-Level Safety: Test for fault conditions—overcurrent, overvoltage, communication loss—across the entire powertrain.
- Plan for Regeneration Management: Coordinate braking strategies and power distribution, especially when the battery is near full charge.
- Engage Suppliers Early: Clarify responsibilities for support and warranty, whether you’re handpicking or integrating.
- Capture Lessons Learned: Document integration challenges and solutions for future reference.
Key takeaways to guide your approach
Choosing between fully integrated and handpicked powertrain systems is a pivotal decision for any OEM embarking on electrification. Here are three key takeaways to guide your approach:
- Prioritize System Compatibility: Whether you choose integrated or handpicked components, ensure all interfaces—electrical, communication, and safety—are clearly defined and validated early in the process.
- Align Risk with Your Strengths: Focus your engineering resources where you have the most expertise. If your team excels in mechanical adaptation, leverage integrated systems to reduce electrical complexity and accelerate development.
- Plan for Long-Term Support: Consider not just initial integration, but also future maintenance, troubleshooting, and warranty management. Integrated solutions often simplify support, while handpicked systems require robust documentation and supplier coordination.
These principles set up the project for technical success and long-term reliability. Watch the full session with Kai Schlüter to see how these strategies play out in real-world OEM electrification projects.
To learn more about how ZAPI GROUP can support your electrification strategy, watch the video below, or connect with a ZAPI GROUP expert today.