Thermal management covers all cooling and heating tasks in an electrified mobile working machine or an electrified commercial vehicle. Almost all the technical conditions are changing in terms of the temperature ranges, heating/cooling power, the number of heating/cooling tasks and the fluids used. The variety of coolants ranges from water glycol to special electrically non-conductive fluids such as transformer oils, NOVEC and demineralised water (DI-water), which is used in particular in the cooling of fuel cells.

Cooling is required in particular for new, electric components such as electric motors, power electronics systems (drive unit frequency converters, DC/DC converters and charging devices), batteries and fuel cells. Heating is needed above all for the cab and the battery system.

Passive coolers and cooling systems

In most cases, with the exception of the battery, the cooling of the electric components can be realised passively – that is, purely to the environment. Alongside customised adjustments, standard components are available here.

Active cooling systems

Because high-energy lithium-ion batteries have an especially limited comfort range, they need to be cooled with an active cooling system – that is, a system with a cooling compressor. In addition to customised developments, we can supply a modular system with various levels of cooling power and various supply voltages. As an option, the active cooling systems can also be equipped with high-voltage heaters that can quickly provide required heat energy, for example to warm up the battery.

More information available on request

With the electrification of mobile working machinery, there is an increasing focus on the efficiency of the entire drive train. This involves not only reducing the operating costs by lowering the consumption of electricity or hydrogen but also limiting the costs incurred for a vehicle battery of sufficient size, particularly in the case of battery-powered electric vehicles. On top of this, battery-powered mobile working machinery gives manufacturers a new way to stand out from the competition, by developing machines and vehicles with particularly high ranges or the ability to handle long working periods without interim charging.

With the installation of high-efficiency electric components like lithium-ion batteries, electric motors and frequency converters, the majority of the power loss is now attributable to the hydraulic system, which makes redesigning the hydraulics an especially important factor in optimising the energy use of the vehicle as a whole. Despite electromechanical drive units gaining importance in certain applications, in very many working functions hydraulics can continue to show its strengths, such as robustness, compact size and cost-effectiveness. Nevertheless, in order to cope with the growing requirements regarding the efficiency of the overall machine, HYDAC supplies solutions in the form of components, subsystems and services relating to increasing efficiency in the drive train. Drawing on decades of experience in component development, HYDAC has established itself in recent years as a reliable partner for efficient drive systems, with the development of hydraulic hybrid systems.

Variable-speed compact power units

Highly integrated hydraulic power units that enable efficient and decentralised supply of hydraulic auxiliary equipment.

DVA mobile

Intelligent variable-speed pump drive units optimised for hydraulic supply in electrified vehicles. Available in 48V technology and HV technology (350V and 650V) in the 5–60 kW power range.

Hydraulic optimisation as a service

HYDAC offers all-inclusive optimisation of your hydraulic system as a service:

• Analysis of sources of loss
• Measurement of existing systems
• Development of optimised concepts
• Performance of simulations of the overall system
• Restructuring of prototype machines

More information available on request

In mobile applications where large amounts of energy or high levels of power are required over a prolonged period, for example in heavy goods vehicles, buses, trains and ships, batteries used on their own quickly reach their limits, both economically and technically. In such cases, the fuel cell used in conjunction with high-pressure tank systems for hydrogen is an effective way to drive and work with zero local emissions. For mobile fuel cell applications and tank systems, HYDAC supplies innovative solution strategies for cooling systems, mounting technology, sensors and filtration. For filling fuel cell vehicles and machines with hydrogen, HYDAC supplies additional components and systems.

Hydrogen filters for mobile applications

Particles entering the fuel-cell vehicle often have serious consequences for the functionality of the tank components and the fuel cells. The most prevalent problem is damage to seals and seal seats of the valves, which can cause leakage and thus failure of the tank system. Drawing on its experience in developing filter systems for hydrogen filling stations, HYDAC can offer filter solutions for protecting components in the tank systems of fuel cell electric vehicles. The HYDAC Chemicron® filter material used provides defined filtration rates and maximum filter integrity.