Sensorless SPMSM Control for Heavy Handling Machines Electrification: An Innovative Proposal

Marco Bassani (), Andrea Toscani and Carlo Concari
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Marco Bassani: Department of Phisics, University of Milan, Via Giovanni Celoria, 16, 20133 Milano, Italy
Andrea Toscani: Department of Engineering and Architecture, University of Parma, Parco Area delle Scienze, 59, 43124 Parma, Italy
Carlo Concari: Department of Engineering and Architecture, University of Parma, Parco Area delle Scienze, 59, 43124 Parma, Italy

Energies, 2025, vol. 18, issue 15, 1-20

Abstract: The electrification of road vehicles is a relatively mature sector, while other areas of mobility, such as construction machinery, are just beginning their transition to electric solutions. This work presents the design and realization of an integrated drive system specifically developed for retrofitting fan drives in heavy machinery, like bulldozers and tractors, utilizing existing 48 VDC batteries. By replacing or complementing internal combustion and hydraulic technologies with electric solutions, significant advantages in efficiency, reduced environmental impact, and versatility can be achieved. Focusing on the fan drive system addresses the critical challenge of thermal management in high ambient temperatures and harsh environments, particularly given the high current requirements for 3 k W -class applications. A sensorless architecture has been selected to enhance reliability by eliminating mechanical position sensors. The developed fan drive has been extensively tested both on a braking bench and in real-world applications, demonstrating its effectiveness and robustness. Future work will extend this prototype to electrify additional onboard hydraulic motors in these machines, further advancing the electrification of heavy-duty equipment and improving overall efficiency and environmental impact.

Keywords: electrification; motor control; field oriented control; sensorless; integrated drive; heavy handling machines (search for similar items in EconPapers)
JEL-codes: Q Q0 Q4 Q40 Q41 Q42 Q43 Q47 Q48 Q49 (search for similar items in EconPapers)
Date: 2025
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