Electrification continues to progress rapidly across industries, yet non-road mobile machinery (NRMM) remains the exception. This lag is evident when compared to sectors such as material handling, where forklifts enjoy a global average of 70% electrification penetration in new models.

The slower adoption rate of NRMM is mainly due to the limited availability of specialized charging solutions to power these vehicles.

Unlike more established sectors, the non-road market has limited global standards and an inherently niche nature, which leaves charging solutions overlooked and underdeveloped.

In ZIVAN's webinar—Unleashing the Power: ZIVAN's SG9 for Challenging Worksites—it was emphasized that by evaluating current solutions, original equipment manufacturers (OEMs) and design engineers can uncover significant market gaps.

3 Obstacles to Electrifying NRMM

Electrified compact machinery, commonly used in construction, agriculture, and other demanding work environments, typically operates at low voltages—48V, 80V, or 96V.  The International Electrotechnical Commission (IEC) classifies anything below 120V as “extra-low” voltages, characterized by: 

• Reduced risk of electric shock during repairs or maintenance
• Alignment with most global regulations governing electric machinery
• Cost-efficiency in construction, installation, and maintenance compared to high-voltage systems

Despite these benefits, compact, low-voltage machinery presents significant logistical challenges when electrifying. Consider three in particular.

#1 - Limited Power and Range

Low-voltage systems introduce additional considerations in battery design and energy storage. For example, batteries operating at lower voltages can store less energy per unit of weight or volume, requiring larger battery packs to meet the same energy demands as higher-voltage systems.

This trade-off results in cascading limitations:

• Less power-dense batteries translate to shorter operational ranges and more frequent recharging cycles.
• Charging equipment not optimized for low-voltage systems often prolongs recharge durations, further reducing equipment availability.
• Frequent and lengthy recharges tether machinery to charging infrastructure, limiting operational flexibility and mobility.

The core bottleneck lies in the absence of charging solutions optimised for low-voltage systems. By nature, such machinery requires an efficient charger readily on hand to offset reduced range. 

#2 - Compatibility Challenges

Compact NRMM faces significant barriers in leveraging existing EV charging infrastructure. While higher-voltage systems can utilize fast-charging electric vehicle supply equipment (EVSE), these stations typically operate at 350V DC or higher—far beyond the maximum 96V used by most NRMM.

AC charging offers compatibility with lower voltages, but comes with excessively long charge times:

• Level 1 equipment requires a minimum of 5 hours for hybrid vehicles and up to 50 hours for battery-powered ones.
• Level 2 equipment, while a significant upgrade, still demands anywhere from 1 to 10 hours for on-road vehicles—often more for industrial equipment.

These limitations highlight another critical gap: the lack of compatible charging solutions capable of delivering efficient recharging for compact NRMM. Without such options, operators and fleet owners face downtime that significantly hinders productivity.

#3 - Space Constraints 

Electrified NRMM occupies a distinct niche in “low-voltage, high-power” applications. Accommodating this demands a balance between energy requirements and physical design limitations—especially since increased battery size is often required.

This creates a significant hurdle for OEM design teams; compact machinery often lacks the space to accommodate dedicated on-board chargers without compromising the machinery’s functionality or ergonomics. 

While stationary chargers offer a potential solution in controlled environments (such as warehouses), they are impractical for unpredictable outdoor applications. Stationary charging equipment is often vulnerable to weather and environmental hazards, and it cannot simply follow NRMM to distant worksites.

Evaluating Existing Charging Solutions 

Several existing solutions aim to address charging needs, but they often fall short when applied to compact NRMM:

• On-board chargers address the needs of smaller fleets, suitable for operations with fewer machines or where extended charging times do not pose an issue. However, their integration frequently compromises machine design by adding weight and consuming valuable space, limiting their practicality for compact machinery.
• Stationary chargers present a reliable option for indoor environments with ample space for dedicated charging rooms. Yet their lack of portability and high infrastructure costs restrict the viability of in-the-field deployment.
• EV charging stations primarily cater to high-voltage vehicles, making them incompatible with the low-voltage nature of most NRMM systems. Additionally, reliance on third-party infrastructure reduces OEM control and scalability over their operations.

While each solution fulfills a specific niche, none fully addresses the unique challenges of NRMM. A significant market gap exists for charging systems tailored to low-voltage, mobile machinery.

The SG9: A Charging Solution Engineered for NRMM

Addressing these gaps in existing solutions, ZIVAN’s SG9 promises to redefine efficiency and practicality for low-voltage machinery. 

As the market’s only modular, mobile off-board charging solution, the SG9 delivers a range of features that address each of the challenges to electrifying NRMM:

• Expanded range and operational viability – The SG9’s modular structure delivers up to 9kW of charging power, significantly reducing recharge time. The charger’s mobile chassis reduces range anxiety by bringing power directly to the worksite, offering OEMs full control over operational logistics.
• Low-voltage optimisation – Designed specifically for 48V, 80V, and 96V system architectures, the SG9 is tailored to the high-power, low-voltage requirements of compact NRMM, ensuring compatibility across the entire fleet.
• Unmatched space-efficiency – As a fully mobile yet off-board charging solution, the SG9 effectively eliminates the need for bulky on-board chargers or extensive stationary infrastructure, allowing fleetwide charging at a fraction of the cost and space.

By incorporating these features, the ZIVAN SG9 effectively addresses power, compatibility, and space constraints—the three primary roadblocks to electrifying compact NRMM. 

In filling these critical market gaps with a single, portable charging solution, the SG9 offers OEMs a cost-effective means to power electrified fleets without compromise.

Charging the Future of NRMM

Oppressive charging times and incompatible infrastructure have slowed electric adoption in compact mobile machinery for far too long. ZIVAN’s SG9 represents the next logical iteration of charging solutions, tailored specifically for the operational and regulatory needs of international OEMs. 

Backed by decades of experience in electrification and a global network of electrification partners, ZIVAN’s innovative solutions and integration expertise ensure each charging system is seamlessly tailored to diverse OEM demands.

To learn how the SG9 can power your electrification journey, watch the full webinar, or contact ZIVAN and request a sample of the SG9.

Sources: 

ZAPI GROUP. How to Accelerate the Adoption of Electrification. https://www.zapigroup.com/en/blog/how-to-accelerate-the-adoption-of-electrification

IEC. IEV ref 851-15-08. https://www.electropedia.org/iev/iev.nsf/display?openform&ievref=851-15-08

U.S. Department of Transportation. Charger Types and Speeds. https://www.transportation.gov/rural/ev/toolkit/ev-basics/charging-speedss  

Media Contact 
Violetta Fulchiati | Marketing & Communication Specialist 
Phone: +39 0522 960593
E-mail: marketing@zivan.it