Heavy Industries

Customer Projects

Expertise in Optimizing Hybrid and Combustion Engines for Heavy Industry & Specialized Vehicles

Through numerous customer projects, we have successfully optimized hybrid and combustion engines for specialized vehicles in heavy industry, mining, construction, and heavy transport. These vehicles must perform reliably under extreme condition be it heat, dust, cold, or continuous load. Our solutions are tailored for high performance, durability, and adaptability, meeting the toughest operational demands.

Noise Reduction for Noise-Sensitive Operation

Technical Challenge: Acoustic Optimization of Modern Powertrains. In noise-critical applications, such as urban construction zones or night operations, both combustion and hybrid systems face complex acoustic issues. Low-frequency engine noise and high-frequency tonal components from inverters or electric motors must be minimized.

Engineering Approach:

Acoustic simulation of powertrain components
Identification of dominant noise sources and structural resonances
Design of damping concepts using viscoelastic materials and acoustic enclosures
Tuning of hybrid operation modes for low-noise electric drive phases in sensitive environments

Robust Powertrain Solutions for Harsh Environments

Technical Challenge: Durability & Maintainability Under Extreme Conditions. Construction, mining, and transport machinery must operate for thousands of hours under harsh conditions. Maintenance access is limited, and components face intense mechanical stress, shocks, and vibrations leading to fatigue and wear.

Engineering Approach:

Virtual durability testing under high load cycles to identify critical fatigue zones
Load analysis of gear systems: optimization of gear forces, clutch actuation, and torque transitions
Shock & vibration simulation for engine mounts and drivetrain components to ensure long-term structural integrity

Hybrid Boost Optimization for Heavy Vehicles

Technical Challenge: On-Demand Power for Critical Driving Scenarios ("Boost Mode"). In steep quarries or rough mining terrain, vehicles must instantly deliver peak power. Combustion engines often lag under sudden load, while hybrid systems can provide immediate electric boost but only if well-integrated.

Engineering Approach:

Boost mode simulation: Analysis of electric assist to eliminate lag in power delivery
Smart energy distribution: Controlled battery boost deployment, synchronized with engine ramp-up
High-load stress testing: Simulation of torque spikes in clutches and gearboxes to prevent overload damage

Mitigating Harmful Vibrations in Electric and Hybrid Drives

Technical Challenge: Vibrations & Resonance in Electric and Mechanical Drivetrains. Abrupt torque steps in electric motors and structural resonances in drivetrains can lead to harmful vibrations—affecting mechanical components, noise levels, and even sensitive electronics.

Engineering Approach:

Drivetrain vibration analysis: Simulation of resonance effects and design of damping strategies
Motor control optimization: Reduction of torque oscillations via advanced control algorithms
Clutch system damping tests: Evaluation of hydraulic and mechanical dampers to minimize vibration impact