Flexibility and scalability help with the electrification of waste disposal vehicles

Flexibility and scalability help with the electrification of waste disposal vehicles

DINTEC GmbH relies on STW technology for the electrification of roll-off tippers in municipal applications. ESX.4 controllers control central vehicle systems, while the TCG-4 communication module handles the connection to the cloud.

Municipal vehicles are predestined for conversion from internal combustion engine drives to battery-electric operation. Their daily journeys are usually short and take them through urban traffic, which means that the advantages of recuperating braking energy into the electrical system can be significant. The infrastructure to recharge the vehicle batteries between deployments is usually available at the depot. These are ideal conditions for equipping roll-off tippers with a battery-electric drive train, for example. These vehicles transport waste in sliding or rollable containers, which they can pull or roll onto the transport base with a hooklift. While retrofitting a roll-off tipper for the waste disposal industry, DINTEC replaced the diesel drivetrain with a battery-powered electric drivetrain.

DINTEC offers solutions and services relating to the electrification of mobile machinery and commercial vehicles for manufacturers, system providers and retrofitters. As an innovation partner, the young company supports established market leaders as well as start-ups on their way to sustainable, climate-friendly applications. Managing Director Michael Schmitt explains the DINTEC approach: "Under the motto 'making electrification work for a sustainable future', we offer our customers help with the electrification of their machines. The systems can be hybrid, battery-electric or fuel cell-based. We can look back on 10 years of experience in the integration of alternative drive concepts in mobile machinery."

Thanks to the flexible DINTEC solution, the vehicle manufacturer can offer a wide range of electrified versions of their vehicles. Michael Schmitt explains the advantages for machine operators: "After retrofitting, the end customer can offer their services emission-free and so already fulfil the legal requirements of the EU Clean Vehicles Directive." The directive stipulates that public authorities, as well as private municipal contractors, must fulfil binding quotas for the procurement of zero-emission vehicles for municipal operations1.

To control the electric drive system, DINTEC relies on components from STW that have proven themselves in municipal technology. An ESX.4cm controller controls the traction drive, while another ESX.4cm monitors and controls the high-voltage system. A further ESX.4cm controller is used to monitor and control the thermal management system and the auxiliary units. An ESX.4cs-gw mobile controller forms the gateway to the vehicle systems, the HMIs in the driver's cabin and the data management system. Thanks to the modularity, performance and large number of interfaces of the individual controllers, DINTEC was able to implement an effective decentralized control system. "Decentralized architectures reduce complexity in many ways. The wiring harness can be lighter. Assembly and servicing are simplified, and ultimately the main vehicle control system is less stressed. With the STW modular system, we can scale our solutions according to customer requirements," explains Michael Schmitt.

Another advantage of the ESX.4 family is the safety certification up to SIL2 / PL d. As the openSYDE system design software already has the same safety certification, functionally safe applications can be realized in a particularly efficient and user-friendly way. The standardized database and Aurix platform of the ESX.4 control systems also contribute to this. openSYDE applications can be easily implemented on different control systems. For example, an application programmed for the ESX.4cs-gw can be seamlessly transferred to an ESX.4cm (or ESX.4cl).

DINTEC uses a TCG-4 communication module to connect to telematics and cloud services. This allows operating data to be tracked and enables remote diagnostics services. This reduces troubleshooting effort in the workshop and thus downtimes. The TCG-4 transmits the vehicle data via 4G/LTE or WiFi. GPS, GLONASS, BEIDOU and GALILEO are provided for localization.

Michael Schmitt concludes: "STW technology is robust, flexible and scalable. We have known the products for many years and both recognize and appreciate their performance. When required, the support team provides us with in-depth expertise. STW is an important partner for us, and make it possible for us to implement electrified and functionally safe systems."

1 https://www.stmb.bayern.de/vum/handlungsfelder/umweltundelektromobilitaet/clean_vehicles_directive/index.php