The electrification of the off-road sector is a concrete and accelerating challenge. Earth-moving machines, mining trucks, refuse collection or industrial handling vehicles: these vehicles often operate in isolated, difficult environments with high performance requirements. In this scenario, electric solutions offer measurable advantages: reduced maintenance costs, greater energy efficiency, lower local emissions and greater operational flexibility. While the automotive sector has now consolidated many solutions for urban mobility, off-road industrial electrification has a completely different profile: low series, high power, extended operating missions and complex environmental conditions. It therefore requires technologies that are robust, configurable but also economically viable.
An evolving sector, between manufacturers and integrators
The off-road market comprises an articulated ecosystem: large international OEMs who develop complete machines, local dealers who handle sales and customisation, engineering companies who support retrofits and customised solutions, and, finally, end customers (industries, mines, municipalities). «Unlike the automotive industry, where technology verticalisation (motors, batteries, inverters produced in-house) is now the norm, in the industrial sector the supply chain remains more open. Electric traction technologies – especially for large vehicles – are supplied by specialised partners capable of managing technical and industrial complexity with a modular approach,» explains Roberto Diana, Country Sales Manager of ABB Traction Italia.
A distinctive aspect of the current market concerns the medium-high power range (from 200 kW to 2 MW), where electrification is already yielding concrete results. In these contexts, the high energy consumption and high operating costs of conventional diesel engines make the electric transition worthwhile, even in the absence of structured incentives.
Strategy and design philosophy
«There are no doubts about the electrical trend – Diana emphasises – but we need technical and economic solutions that stand the test of time». And this is where ABB’s philosophy comes in: not to chase every performance record, but to optimise the most relevant parameters for industrial customers, balancing performance, durability and cost.
One of the central issues for the large-scale adoption of off-road electric solutions is the cost-benefit ratio. In a sector where volumes remain limited and customisation is high, technologies must balance high performance with economic sustainability. «The winning approach – says Diana – is based on modular and standardised solutions, capable of adapting to several vehicle types without resorting to costly customisation each time». This allows users to achieve good performance with controllable costs and suppliers to amortise investments over several projects. In this vision, the design of traction systems does not aim to maximise every single parameter, but to optimise those that really matter: efficiency, autonomy, reliability, ease of integration, recharging times and, of course, the economic return for the customer.
The importance of modularity and integration: three elements one system
ABB is one of the few companies able to offer all three key components for powertrain electrification: motor, inverter and batteries. This integration allows vehicle manufacturers to rely on a single technology partner for the entire powertrain chain, with concrete advantages in terms of compatibility, technical support and development time. Furthermore, components are tested not only individually but also as a complete system, ensuring harmonious and reliable operation from the very first use. For this reason, adopting the entire ABB package is a strategic choice for those seeking reduced design risks and stable performance over time.
ABB’s offering is designed to be modular and flexible, suitable for different application contexts and power ranges, with a particular focus on the needs of the off-road sector. Products can be configured to meet specific regional, environmental or operational needs, accompanying companies in the transition to more sustainable mobility models. The aim is to provide not only components, but complete and scalable solutions, capable of combining technological innovation with economic sustainability, in a long-term perspective.
AMXE engines: compact and durable power for every environment
At the heart of the ABB traction chain are the AMXE synchronous, permanent magnet motors. They are water-cooled motors with a fully enclosed construction, ideal for dusty environments and extreme conditions. This structure ensures long life and high power density, while the advanced design optimises overall efficiency. They offer high efficiency (up to 97.1 %). The range covers continuous powers from 28 to around 233 kW, with customised solutions for higher applications, often derived from ABB’s railway experience.
The motors in the AMXE range offer performance that can be configured to suit application needs, thanks to the ability to customise mechanical interfaces, windings and operating voltages. This flexibility allows the right balance of power, efficiency and dynamics to be achieved, optimising overall vehicle performance. Among their main advantages is their high torque capacity, which ensures prompt response and superior productivity, even under the most demanding operating conditions. The motors are designed to withstand shock loads, intense vibrations and extreme temperature fluctuations, making them ideal for hostile environments such as off-road. The various IP protection classes available ensure complete protection against moisture and dust, while long-term reliability is guaranteed through rigorous testing and advanced simulations, confirming the robustness of the design and build quality.
A modular and industrialised approach
Unlike other players who offer completely customised solutions, ABB has chosen a modular approach, industrialising key components to ensure:
- reliability certified by internal tests and simulations;
- low costs thanks to scalable production;
- application flexibility to cover different vehicle types.
«The balance between performance and economic sustainability is central – explains Diana – It would make no sense to design from scratch every time. Our proposal is optimised to offer the best technical-economic compromise available today».
A global partner for sustainable mobility
In addition to technology, ABB offers a significant competitive advantage. Diana concludes: «As a globally present company, ABB offers an already operational global service network shared with the industrial business. This is a valuable asset for OEMs and integrators operating worldwide, from mining sites in South America to construction sites in Northern Europe. The objective is not just to supply components, but to accompany the customer through the electrical transition, offering technical support, system integration and after-sales warranty».
Compact (only 15 kg) and modular, these inverters are ideal for off-road electric vehicles, adaptable in multiple configurations to power even every motor wheel . In addition, complete integration with motor and battery allows ABB to provide a turnkey, optimised and tested package. They are designed to withstand the harshest environments thanks to their high vibration tolerance and liquid cooling. There are three possible modes of use:
• inverter mode to control motor speed and torque;
• line converter mode to transform the AC voltage from the mains into a DC voltage for the vehicle (on-board charger functionality);
• DC/DC mode for connecting fuel cells or energy charging systems.
ABB’s traction batteries, based on LTO (Lithium Titanate Oxide) cells, are designed for heavy-duty applications. They do not excel in energy density, but make up for it with:
- life cycles over 20,000, four times longer than automotive cells;
- high power density;
- ultra-fast charging, ideal for controlled environments such as mines.
The system is modular, with 17.7-40.6 kWh units that can be combined in parallel to suit different mission profiles.
ABB also accompanies the customer in analysing energy requirements and optimising the entire system. They can also be used in hybrid or diesel-powered off-road vehicles, where they also provide the energy for starting the heat engine, as well as supporting peak power and energy recovery. This function improves efficiency and reduces consumption and emissions in critical phases, such as cold starts. Even in non-fully electric vehicles, batteries thus play a strategic role in the transition to more sustainable mobility.
