Suncar ZE150W excavator | Digest E-Mobility Engineering | November/December 2023 57 Its upper carriage contains the HV battery pack, the Interflow 500 DC charging interface and connector, the Fusion 800M HVDU and the inverters, motors, pumps and/or gearing for all the non-traction HV loads. One invertermotor set drives the original hydraulic pumps for the stick, bucket and other energy consumers, such as the backfill blade. A second set drives the HELAX pump for the EH boom actuator, while a third powers the motor that turns the slewing ring via its transmission. The upper carriage also contains an LV battery feeding an LVDU that powers the inverter and motor for the brake and pilot pump as well as other LV consumers. The undercarriage contains the Fusion 800S that serves the traction motor with its mechanical transmission and drives, the AC inlet, AC fuse box and AC charger, an LV battery, power distribution unit and various LV consumers. Like most EVs, the ZE150W is quite software-intensive. Much of the code is embedded in the subsystems, but the overall control architecture and HMI are also highly software-reliant. “For the machine to operate efficiently, adaptive control of the thermal management, all the electric drives and the HMI is crucial,” Baettig says. “The more direct-electric drives there are, the more software is needed for coordinated operation of all subsystems.” Software oversight and assistance The remote management system from Suncar, known as Insight, is designed to allow operations managers to check on the status of individual machines as well as entire fleets. The GUI provides a map view with GPS positions of all the machines, while mobile comms that can use GSM, GPRS, 3G, 4G and wi-fi networks enable live support, including troubleshooting and fault analysis. The system supports access to operational data by approved third parties, records all the data and immediately reports errors via email over the mobile network. It also provides access to the machine for software upgrades and parameter adjustments over the air, protected by a virtual private network. The Insight package includes a Linuxbased IoT gateway with pre-processing of operational data, a back-up battery and full recording of CAN bus activity onto an SD card. Its remote monitoring function provides a graphic display of operating data in a browser, including a live representation of the machine’s cockpit, for example. Like all Suncar’s excavators, the ZE150W can be equipped with its inhouse developed Movasyst excavator assistance system. It consists of the mutually compatible subsystems Movlimit, Movcontrol and Moview. Movlimit is the lifting and slewing limitation system for use in restricted spaces containing significant hazards, such as near railway tracks. Movcontrol is an excavator automation system designed to help the operator with repetitive tasks. For example, it allows the creation of flat surfaces and slopes at specified angles of inclination with a single joystick movement from the operator. Moview is a visualisation system that shows the machine operator the exact position of the edge of the bucket both graphically and numerically, eliminating the need to install batter boards that define the edges and corners of a set of foundations, for example. The base vehicles for the two prototypes are currently being disassembled in order to make space for the new components and system containers. The first prototype will include the main electric drive that replaces the diesel, plus electric traction drives, while the second will have these and add the electric slewing drive and the EH linear axis. The first two machines are scheduled to reach their customers in the second quarter of next year, with the start of small-scale series production expected soon after that. Some key suppliers Battery system: BorgWarner Akasol Electric motors for hydraulic pumps: Bonfiglioli Germany High-voltage motors and inverters: Dana Hydroelectric linear axis: Bucher Hydraulics Laser-cut and sheet-metal parts and assemblies: eMDe Blechfabrik Other electric motors: ZF Power electronics, charging and drive technology: BRUSA HyPower Sundry electrical components: Bosch Rexroth Switzerland Thermal management system: Rheinmetall Invent HELAX electro-hydraulic systems combine motor, pump, accumulator, hosing and linear actuator in a dedicated loop that eliminates valving and associated energy losses (Courtesy of Bucher Hydraulics)
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