As a specialist in providing lithium battery OEM solutions, we work with engineering companies to provide electrical conversion solutions for diesel conversion projects, enabling diesel-powered construction equipment, excavators, and port cranes to run on electricity, reducing fuel costs for machinery.
This comprehensive guide introduces the advantages of electric conversion, applicable machinery, key OEM lithium battery solutions, and the critical steps for successful implementation. By understanding these aspects, you can ensure a smooth transition to a more sustainable and cost-effective operating model.
This article focuses on the following aspects:
- Advantages of electric conversion of diesel-powered equipment
- Types of machinery suitable for diesel-electric conversion
- Key lithium battery solutions for diesel conversion
- Technical requirements for lithium battery integration
- Safety and reliability of diesel vehicle electrification
- Steps to implement diesel-to-electric conversion using OEM lithium battery solutions
Ready? Let’s get started!
Advantages of electric conversion of diesel-powered equipment
Lower maintenance costs
Reducing maintenance costs is one of the most essential advantages of converting a diesel-powered unit to an electric drive. Diesel engines have various wearing parts that require regular maintenance, including oil changes, filter replacements, and engine tuning. In contrast, electric motors have fewer wearing parts and wear less, so maintenance requirements are lower.
Improved energy efficiency and reduced emissions
Electric motors are naturally much more reliable than diesel engines. While a regular diesel engine only works at 30-35% efficiency, an electric motor can achieve 85-90%. This increase in power efficiency means that electrical equipment can do the same job with less power, reducing operating costs.
Sustainability
The conversion of diesel-powered appliances to electricity aligns with international sustainability goals. Switching to electricity reduces dependency on fossil fuels, which are finite resources and a significant contributor to greenhouse gas emissions. By integrating OEM lithium battery services directly into these conversions, we can further enhance the appliances’ sustainability. Lithium batteries are known for their high energy density, long cycle life, and recyclability, making them ideal for sustainable electricity storage.
Advantage | Diesel | Electric |
Upkeep Costs | High | Reduced |
Energy Efficiency | 30-35% | 85-90% |
Emissions | High | Absolutely no |
Sustainability | Reduced | High |
Machines suitable for diesel-electric conversion
Excavators
Excavators are prime candidates for diesel-electric conversion, as they are used in various applications in the construction and mining sectors. Converting these machines to electric drive can significantly reduce fuel costs and improve functional performance. Electric excavators are quieter in operation, which is helpful on urban construction sites with strict noise regulations. In addition, using OEM lithium batteries ensures a reliable and stable power supply, which is essential for heavy-duty tasks.
Loaders
Both wheeled and tracked loaders are also suitable for conversion to electric power. These machines are commonly used for material handling and construction. With fewer moving parts and no combustion engine, the conversion to electric power reduces the maintenance costs of loaders. High-capacity OEM lithium batteries ensure that loaders can operate for long periods without the need for regular charging, thereby maintaining high performance.
Cranes
Cranes, especially those used in the commercial, building, and construction sectors, can benefit significantly from switching from diesel to electric power. Electric cranes are more environmentally friendly, with improved energy efficiency and reduced emissions. Original lithium-ion battery packs provide a stable power source, essential for the safe operation of cranes. In addition, electric cranes have fewer hydraulic systems, which reduces the risk of leaks and simplifies maintenance.
Material handling vehicles
Material handling trucks(AGV and AMR, Forklift) are widely used in recycling, waste monitoring, and port operations and are well suited for conversion to electric drive. These vehicles often operate in enclosed or densely populated areas, where exhaust fumes and noise are serious problems. Electric material handling trucks equipped with OEM lithium batteries run quieter and produce no emissions, improving the working environment and reducing carbon emissions.
Agricultural and industrial vehicles
Agricultural and commercial trucks, such as tractors and forklifts, are also excellent candidates for diesel-to-electric conversion. These vehicles can take advantage of improved power efficiency and reduce the expense of power-related features. OEM lithium batteries provide the power and reliability needed to complete various agricultural and industrial tasks, from plowing fields to lifting heavy loads. In these markets, switching to electric power helps meet sustainability goals and the growing demand for green technology in agriculture and the marketplace.
Lithium battery solutions for diesel conversion
When considering the electrification of diesel vehicles, selecting the right OEM lithium battery solution is critical to ensuring optimal performance and reliability. Here, we will introduce the various OEM lithium battery innovations, their benefits, and the essential factors to consider when incorporating them.
Lithium batteries types
A variety of lithium battery types are commonly used in the electrification of diesel vehicles, each with their own unique benefits:
Battery Type | Power Density (Wh/kg) | Cycle Life | Applications |
Lithium Iron Phosphate (LiFePO4) | 90-160 | 2000-5000 cycles | Product handlers, agricultural vehicles |
Lithium Nickel Manganese Cobalt Oxide (NMC) | 150-220 | 1000-2000 cycles | Excavators, loaders |
Lithium Titanate (LTO) | 70-80 | 5000-10000 cycles | Cranes, industrial vehicles |
Advantages of lithium batteries
Lithium batteries offer the following advantages over traditional lead-acid batteries and other energy storage space solutions.
- Higher energy density: OEM lithium batteries have a better energy storage capacity, which means longer operating times at a comparable cost.
- Longer cycle life: These batteries can withstand more charge and discharge cycles, reducing replacement frequency and ongoing costs.
- Faster charging: Lithium batteries charge faster, which reduces downtime and improves overall productivity.
- Lighter weight: Lithium batteries are lighter, which can improve the efficiency and mobility of retrofitted machinery.
Considerations when integrating
- Voltage and capacity requirements: Ensure the battery’s voltage and capacity meet the retrofitted equipment’s requirements.
- Thermal management: Implement a reliable air conditioning system to manage the heat generated during battery operation and charging.
- Battery management system (BMS): Use a durable BMS to check and control the battery’s efficiency to ensure safety and reliability.
- Compatibility: Verify that the battery is compatible with the device’s electrical and mechanical systems.
Customized solutions and manufacturer support
- Customized battery packs: Designed to meet the unique dimensions, appearance, voltage, capacity, BMS, internal structure, cells, etc., of the device.
- Technical support: Assist with installing the battery system and the calibration equalization process.
- After-sales service: Ongoing assistance and maintenance to ensure the service life and efficiency of the battery system.
Technical requirements for lithium-ion battery integration
Battery specifications and compatibility
Key factors include the voltage, capacity and discharge of the battery. These specifications must be matched to the power requirements and operating requirements of the modified tool. In addition, compatibility with existing electrical systems and interfaces is important to avoid comprehensive adjustments.
Energy density and power output
The energy density of lithium batteries is a determining factor in their suitability for diesel-to-electric conversion. Higher power densities allow for more compact and lighter battery packs. The battery’s power output must meet the machine’s peak power demand.
Thermal management
Lithium batteries generate heat during operation, which, if not properly managed, can lead to overheating and potential safety hazards. Integrating advanced air conditioning systems, such as fluid cooling or phase change products, helps maintain an optimal operating temperature and prolong battery life.
Battery management system (BMS)
The BMS ensures risk-free operation by checking criteria such as voltage, current, temperature levels, and state of charge. It also prevents overcharging, deep discharging, and short circuits. For the diesel-to-electric conversion, the BMS must be compatible with the control system of the device and be able to be used in conjunction with other digital components.
Safety and reliability in the electrification of diesel vehicles
Understanding safety standards
Lithium-ion battery packs must meet stringent safety and reliability requirements, including those set by the International Electrotechnical Commission (IEC) and companies such as Underwriters Laboratories (UL). Compliance with these standards helps to reduce the risks associated with battery failure, thermal runaway, and electrical hazards.
Battery management system (BMS)
A robust battery management system (BMS) is essential to safely operate lithium batteries in power conversion. The BMS monitors the battery’s charge, temperature, and overall health. It ensures that each battery cell operates within a risk-free parameter range, preventing overcharging, deep discharging, and overheating.
Thermal management
Effective thermal management is essential to maintain the reliability of lithium batteries. An appropriate air conditioning system, such as liquid or advanced air cooling, helps dissipate the heat generated throughout the process. This prevents thermal runaway and extends the battery’s lifespan.
Emergency protocols
These include automatic shut-down mechanisms in case of a severe fault, fire suppression systems, and transparent battery handling and disposal standards. Training employees in these protocols improves overall safety.
Information monitoring and diagnostics
Advanced information monitoring and diagnostic equipment can track battery efficiency in real-time. These tools can understand the battery’s health, allowing for predictive maintenance, early detection of potential problems, reduced downtime, and improved integrity.
Lasting partnerships and after-sales service
A successful retrofit mission extends beyond the initial implementation phase. A long-term relationship with an OEM lithium battery manufacturer ensures ongoing support and after-sales service. This includes regular maintenance, efficiency tracking, and timely upgrades, which are essential to maintain the efficiency and integrity of electrical equipment gradually.
Steps to implement a diesel-to-electric conversion with an OEM lithium battery solution
1. Evaluate current diesel equipment
The first step in the diesel-to-electric conversion process is a thorough analysis of the existing diesel-powered machinery. This includes reviewing the functional requirements of the tools, the batch profile, and the duty cycle.
2. Identifying the right OEM lithium battery solution
Once the functional requirements are clear, the next step is determining the ideal OEM lithium battery service. This involves comparing battery specifications such as energy density, voltage, capacity, and cycle life. Variables to consider include
3. Create an integration framework
Designing an assimilation framework is an essential step. This involves creating a blueprint that explains how the OEM lithium battery will be integrated into the existing vehicle. The battery monitoring system (BMS), cooling system, and safety devices are vital components to consider.
4. Source the necessary components
Once the layout is complete, the next step is to source the necessary components. This includes the lithium battery, electric motor, control system, and other ancillary components.
5. Carry out the conversion
Once all the components are ready, the actual conversion process can begin. This involves removing the diesel engine and associated components, installing the electric motor, integrating the OEM lithium battery, and connecting the control system.
6. Inspection and validation
After installation, rigorous testing and validation must be carried out. This includes efficiency testing under various batch issues, safety checks, and efficiency assessments. Any inconsistencies or issues identified during testing should be resolved as soon as possible to ensure the integrity of the conversion.
7. Training and support
Finally, training operators and maintenance personnel on the new electric system is essential. Detailed training on the operation, maintenance, and troubleshooting of the OEM lithium battery option can ensure the retrofitted equipment has the desired performance and durability. In addition, developing a support system with the OEM lithium battery manufacturer can provide ongoing support and updates.
Conclusion
Using lithium battery services to transition from diesel-driven machines to electric systems helps business owners or diesel conversion projects and provides electrical conversion companies with experience in the battery industry, thereby improving power efficiency, reducing exhaust emissions, lowering maintenance costs, and being sustainable.
As a lithium battery industry with 16 years of OEM and ODM experience, Keheng can become your high-quality partner on the road to success and help you provide tailored services and assistance.
