Everything You Need to Know About Electric Wheel Loaders

Electric wheel loaders are an innovative and eco-friendly alternative to traditional diesel-powered wheel loaders. As the construction and industrial sectors increasingly focus on sustainability and reducing emissions, electric wheel loaders have gained popularity. In this article, we will cover everything you need to know about electric wheel loaders, including their features, advantages, applications, and considerations.

1. Features:

   - Electric Motor: Electric wheel loaders are powered by electric motors instead of internal combustion engines. These motors are typically powered by lithium-ion batteries, which provide clean and efficient energy.

   - Battery Technology: Lithium-ion batteries used in electric wheel loaders have advanced significantly in recent years, offering higher energy density, longer operating times, and improved charging capabilities.

   - Regenerative Braking: Electric wheel loaders often feature regenerative braking systems that capture and convert braking energy into electrical energy. This energy is then used to recharge the batteries, increasing overall efficiency.

   - Reduced Noise and Vibration: Electric wheel loaders produce significantly less noise and vibration compared to their diesel counterparts. This makes them suitable for applications in noise-sensitive areas or during nighttime operations.

   - Zero Emissions: One of the key features of electric wheel loaders is their zero-emission operation. They do not produce harmful exhaust emissions, contributing to cleaner air quality and reduced environmental impact.

NZE55F 316kwh electric wheel loader

2. Advantages:

   - Environmental Benefits: Electric wheel loaders have a significantly lower carbon footprint compared to diesel-powered loaders. By eliminating exhaust emissions, they help reduce air pollution and greenhouse gas emissions, contributing to a more sustainable and environmentally friendly operation.

   - Cost Savings: Although electric wheel loaders may have a higher upfront cost compared to diesel models, they offer long-term cost savings. Electric motors are more energy-efficient, resulting in lower operating costs over the machine's lifespan. Additionally, electric wheel loaders require less maintenance, as they have fewer components prone to wear and tear.

   - Operator Comfort: Electric wheel loaders provide a quieter and smoother operation due to their reduced noise and vibration levels. This creates a more comfortable working environment for operators, improving productivity and reducing fatigue.

   - Energy Efficiency: Electric wheel loaders are more energy-efficient compared to diesel counterparts. The electric drivetrain allows for precise control over power output, resulting in optimized energy usage and reduced energy waste. Regenerative braking systems further enhance energy efficiency by harnessing and reusing energy that would otherwise be lost.

   - Government Incentives: In many regions, there are government incentives, tax credits, or subsidies available for the purchase and use of electric machinery. Taking advantage of these incentives can help offset the initial higher cost of electric wheel loaders.

3. Applications:

   - Construction Sites: Electric wheel loaders are suitable for various construction applications, including material handling, loading/unloading, and transporting materials within job sites. They can efficiently handle tasks such as moving earth, gravel, sand, and construction debris.

   - Urban Areas: Electric wheel loaders are particularly beneficial in urban areas with strict emissions regulations and noise restrictions. They can be used for urban construction projects, road maintenance, landscaping, and urban infrastructure development.

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   - Indoor Operations: The zero-emission operation of electric wheel loaders makes them ideal for indoor applications where air quality and ventilation are crucial. They can be used in warehouses, manufacturing facilities, recycling centers, and indoor construction projects.

   - Green Building Projects: Electric wheel loaders align well with green building practices and LEED certification requirements. They contribute to the sustainability goals of green building projects by minimizing emissions and promoting renewable energy use.

4. Considerations:

   - Range and Charging: Electric wheel loaders are limited by battery range and charging infrastructure. Consider the operating time required for your specific applications and ensure that there is access to charging facilities or opportunities for battery swapping if needed.

   - Initial Investment: Electric wheel loaders generally have a higher upfront cost compared to diesel models. Evaluate the total cost of ownership, including potential fuel savings, operating costs, and available incentives, to determine the financial viability of electric wheel loaders for your business.

   - Application Suitability: Assess the specific tasks and conditions in which you will use the wheel loader. Electric models are most suitable for shorter operating cycles and applications where zero emissions and reduced noise are critical. Evaluate whether the electric wheel loader's performance, power, and range meet your requirements.

   - Charging Infrastructure: Consider the availability and feasibility of establishing charging infrastructure in your operating area. Assess the electrical capacity, access to charging stations, and potential costs involved in installing the necessary infrastructure.

Electric wheel loaders offer a cleaner and more sustainable solution for various applications. Their features, such as zero emissions, reduced noise, energy efficiency, and cost savings, make them an attractive choice for environmentally conscious businesses. By considering factors like range, charging infrastructure, initial investment, and application suitability, you can determine if electric wheel loaders are the right choice for your specific needs.

1. Introduction

As an off-road vehicle, the wheel loader (WL) shares numerous similarities in drivetrain and transmission configuration with a four-wheel passenger car. However, the conventional WL is powered by a diesel engine which contributes to large exhaust emission and fuel consumption, as well as working noise. Enhancing fuel efficiency and adopting cleaner energy sources have emerged as pivotal strategies for achieving energy savings and emissions reduction over the past few decades, encompassing various sectors, including the automotive industry [ 1 4 ]. The electric wheel loader (EWL) represents a novel category of earthmoving machinery driven by electric motors, playing a crucial role in construction sites, mines, and ports [ 5 ]. The statistics from the China Construction Machinery Association (CAMA) reveal that the sales volume of EWLs in China reached 3595 units in the year 2023, with a year-over-year growth of about 210% [ 6 ]. Table 1 lists world-famous corporations and their EWL products.

The EWL has become a prominent research topic in recent years [ 7 10 ]; researchers need to be aware of structural changes not only in the powertrain but also in the hydraulic system. Figure 1 shows the comparison of engine-drive WLs and electric-drive WLs in subsystems. Other than the power sources that are different, the engine-powered WL typically incorporates a multi-ratio transmission and torque converter, whereas an electric WL is commonly equipped with a fixed-ratio gear reducer, to transmit torque and enlarge it.

Since the powertrain is no longer diesel-powered, an electric motor is applied to drive the hydraulic system in EWLs [ 11 ]. The hydraulic system provides hydraulic energy for the working unit to shovel and dump materials, causing the WL’s center of gravity to undergo more frequent changes than that of a passenger car. This results in frequent variations in the drive torque requirements during its operational processes. In a diesel-powered WL, the front and rear axles are interconnected by a transmission shaft, enabling increased drive torque for all four wheels, as a single engine serves as the power source. However, this construction introduces challenges, such as the potential for tire deformation leading to sliding on either the front or rear wheel, owing to varying loads on the axles. Additionally, during shoveling conditions, the forward shift in the gravity center may lift the rear wheels, decreasing vertical pressure and reducing the adhesion force between the rear wheel and the ground either in a conventional engine-drive WL or an electric WL. This scenario can result in wheel slippage under sufficient drive force on the wheels. Both situations contribute to the generation of parasitic power, leading to a substantial consumption of energy. Additionally, the forward shift in the gravity center will cause an increase in vertical load on the front wheels. If the torque distribution on the drive axles is not controlled properly, the energy waste and tire wear will be a big cost for WLs.

Through the discussion and comparison of energy-saving research in WLs, Fei et al. proposed that the control of torque distribution between the front and rear motors of an EWL is essential for achieving energy savings in WL operations [ 12 ]. Torque distribution research on electric vehicles covers topics ranging from two-axle drive [ 13 14 ] to four-wheel independent drive [ 15 17 ]. In these research fields on EWLs, Yang et al. [ 18 ] utilized a group of nonlinear constraint optimization algorithms on the longitudinal dynamics model of EWLs, revealing heightened energy efficiency and improved performance through simulation. Gao et al. [ 19 ] employed an unscented Kalman filter to estimate the shoveling load, enabling the calculation of vertical forces on tires. This approach was utilized to distribute drive torque and ultimately reduce tire slippage during shoveling conditions. Wang et al. [ 20 ] proposed a torque distribution control strategy grounded in the optimal efficiency of the motor, achieving a 7–12% reduction in energy consumption through simulation when compared to other control strategies. However, in [ 19 ], the drive force of wheels was not taken into consideration, which is a vital factor of the shoveling effect. In [ 18 ] and [ 20 ], they did not test on any EWLs in practical working environments.

Therefore, this study aims to analyze the characteristics of EWLs based on their construction and working processes. The analysis includes examining the relationship between the hydraulic pressure in the base chamber of the tilt cylinder and the force on the bucket. Additionally, this study tests the relationship between the axle load of the front and the hydraulic pressure in the base chamber of the tilt cylinder using a 5 ton rated load EWL and a 15 ton rated load EWL. A new type of dual-motor drive EWL is designed by increasing the transmission ratio of the front drivetrain, and an axle load-based torque control strategy is proposed and tested on the newly designed EWL in running and shoveling conditions.

The contribution of this study is as follows: the linear relationship between the axle load and the hydraulic pressure of the working unit is analyzed and tested. This understanding facilitates the distribution of the drive torque in EWLs without the need for complex algorithms. A distributed drive EWL is designed and manufactured, featuring distinct transmission ratios for the front and rear drivetrains, with the front transmission ratio nearly twice that of the rear. Tests for the new dual-motor drive EWL are conducted under both running and shoveling conditions. The proposed drive torque distribution strategy is applied during the shoveling test, confirming its effectiveness in achieving sufficient drive force and reducing tire slippage when distributing torque according to the axle load.

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