Mobile work machines are electrifying rapidly — a new research environment supports the industry’s product development

Mobile work machines used in mines, forests, ports and other demanding locations are in the midst of a major transformation as combustion engines are replaced by electric powertrains. The green transition and digitalisation are accelerating development in the sector: electrification improves the efficiency, energy efficiency and intelligent control of machines, as well as reduces component sizes and emissions.

A full-scale development and testing environment for mobile work machines has been built on Aalto University’s premises.  The LEMMI equipment (Large-scale Electric Mobile Machine Infrastructure), now a part of the national research infrastructure, has been developed in Co-Innovation projects funded by Business Finland. Aalto leads the projects, in collaboration with Tampere University and a total of 18 companies.

The exceptionally extensive company network covers leading Finnish companies involved in the development of mobile work machines and related technologies. The equipment is fitted with subsystems and components supplied by partner companies. 

‘The research environment combines full-scale equipment and virtual operating environments. It enables assessment of energy efficiency, controllability and performance in conditions that correspond to real-world use,’ says Aalto University Professor Petri Kuosmanen.

Towards more compact and efficient electric drives

The ongoing Drive Forward project focuses on the dimensioning and design of electrohydraulic drives for mobile work machines. The aim is to find solutions that make it possible to implement systems as compactly as possible without unnecessary oversizing.

‘With the right kind of modelling and careful design, electric drives can be precisely matched to real working cycles, so that the components have sufficient performance but are not unnecessarily large, heavy or expensive,’ summarises Ponsse’s Director of Research and Programs Kalle Einola.

For ABB, the research environment offers an opportunity to study the dimensioning limits and optimisation of electric motors and frequency converters.

‘This is a unique research environment for Finnish work machine and component manufacturers, even on an international scale. It can be used to study the behaviour and technical limits of work machines in realistic conditions, which strengthens our competitiveness in global markets,’ says Matti Kauhanen, technology director at ABB Drives. 

‘One key part of the project is to find out how artificial intelligence can be used in the design of work machines and their electric hydraulic systems,’ Professor Kuosmanen says.

Because the equipment is located in Aalto’s own premises, the researchers have full control of and insight into it. This enables controlled and repeatable experiments.

‘At the same time, the subsystems of the equipment – such as the powertrain, cooling and work hydraulics – are realistic enough from an industrial perspective that companies recognise them from their own products,’ says Mikko Valtee from Sandvik.

According to Valtee, the research environment also plays an important role in university teaching, which educates future experts for industry.