Prototype Wheel Loader Switches From Fuel Cell to Battery Power

• Develon introduces the DL250 FCEV prototype wheel loader at Intermat, showcasing its ability to switch between hydrogen fuel cell and battery electric power sources.

• The DL250 FCEV features a unique design with a 'Function Area' for equipment operation and a 'Power Source Area' that can house either a fuel cell Powerpack or a battery pack, enhancing its versatility.

• The prototype addresses key challenges in zero-emission vehicle operation, including battery cost, charging time, and infrastructure needs, by offering a modular 'Power Source Area' for easy power system swaps.

• Enhanced safety and usability are ensured through the integration of a Dual Camera System, compensating for the increased rear size and maintaining excellent visibility for operators.

• The DL250 FCEV achieves high efficiency in operation with its electrically driven e-Working and e-Travel systems, promising performance equal to or superior to traditional combustion engine loaders.

• Despite the power source used, the DL250 FCEV maintains over 8 hours of operation on a full charge, demonstrating the effectiveness of Develon's flexible and efficient design approach.

Develon is showing a number of new innovations on the company’s stand at Intermat, including those in the Future Energies Area of the stand. One of the unique machines in this area is the prototype DL250 FCEV (Fuel Cell Electric Vehicle) which has a versatile, single platform design that allows it to be equipped with a fuel cell powerpack running on hydrogen, but offers the ability to transition to a BEV (Battery Electric Vehicle) by installing a battery pack.

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The design of the DL250 FCEV prototype offers solutions to some of the key challenges in operating zero emission vehicles such as battery cost, battery charging time, the infrastructure for rapid battery charging and the hydrogen refuelling infrastructure. These challenges have varying characteristics across different regions. Hence, a strategy that can cater to various electric power systems, such as BEV and FCEV using a single platform is essential. Despite being designed based around the FCEV system, the DL250 FCEV wheel loader allows easy expansion to the BEV system.

Electric Drive with Flexible Platform

The electric solution in the DL250 FCEV is based around segmenting the machine into two primary areas: the 'Function Area', responsible for the operation of equipment with a smaller battery capacity, and the 'Power Source Area', serving as the equipment's main power hub. This unique design allows the 'Power Source Area' to be versatile: when equipped with a fuel cell Powerpack, the equipment operates as an FCEV system running on hydrogen; but when installed with a battery, it transitions into a BEV system. This means from a singular platform, it is possible to implement a diverse range of electric power systems.

In the DL250 FCEV, it is configured with a fuel cell Powerpack and a hydrogen tank, manifesting as an FCEV system. Yet, with the flexibility of the design, this can be readily altered by fitting a battery to transform it into a BEV system. A challenge that arises, especially in equipment similar to electric vehicles with large battery capacities, is the extended charging time relative to equipment operation.

However, the Develon solution lies in the modularity of the 'Power Source Area'. Unlike the fixed 'Function Area', the 'Power Source Area' is designed for easy replacement, thereby addressing the charging time issue with a battery swap method, ensuring equipment remains at the forefront of efficiency and adaptability.

Excellent Visibility

The DL250 FCEV, when compared to traditional internal combustion engine wheel loaders of equivalent weight and performance, has a more substantial rear size. This enlargement results from the replacement of spaces previously occupied by the engine and fuel tank with the Powerpack, which can potentially hinder visibility in the equipment's operation due to the increased size of the Power Source Area.

To mitigate this visibility issue, Develon has equipped the machine with cameras to enhance rearward sightlines. This ensures that regardless of the size of the Powerpack installed in the Power Source Area, operators experience no significant obstructions to their field of view.

Additionally, anticipating the possibility of Power Source Area replacements, Develon has integrated a Dual Camera System. This design ensures unobstructed rear visibility even when components from this area are removed, further enhancing the equipment's user-friendliness and safety.

High Efficiency Operation

Both the front operations and driving tasks of the wheel loader have been equipped with electrically driven systems: the e-Working system and the e-Travel system. The e-Working system ensures performance equal to or better than existing internal combustion engine equipment. As for the e-Travel system, it leverages regenerative driving to enhance efficiency. It also offers rapid responsiveness compared to conventional combustion engines, enabling users to execute tasks more swiftly.

The DL250 FCEV, which currently uses hydrogen as its power source, can operate for over 8 hours on a full charge. Should it be converted to use a battery as its power source, transitioning into a BEV system, it still maintains the equivalent performance, testifying to the versatility and efficiency of Develon’s design.