Danfoss unit gains grant to test Dextreme Max

Sept. 16, 2023
U.K. grant of $6.1 million to fund testing in a 30-ton excavator.

Danfoss Scotland will use a $6.1 million grant to validate its Dextreme Max system in a 30-ton electric excavator, which it expects will reduce energy consumption by 50%.

The U.K. Government’s Department for Energy Security & Net Zero provides the grant through the Red Diesel Replacement Phase 2 Competition. The program provides funding for projects developing low-carbon alternatives to red diesel for the construction, mining, and quarrying sectors.

Read also: Danfoss trial to test excavator efficiency

“Electrification offers a promising route to decarbonization, but the immense power consumption of excavators means that expensive batteries and charging infrastructure are required,” said Leif Bruhn, head of digital displacement, Danfoss Power Solutions, in a statement. “This cost is a major barrier to wider adoption of electric machines.”

“Excavators account for 50% of emissions from construction machinery, and hydraulic systems within excavators waste as much as 70% of the useful power delivered by the engine,” he said. “By dramatically improving excavator energy efficiency, we can reduce the battery size and charging energy required to do the same amount of work. This will bring down costs, thus accelerating the transition to zero-carbon energy sources. The solution to a greener future in construction is efficiency. If we can prove it’s possible in excavators, we can conceivably accelerate the electrification of all large construction machinery.”

Danfoss’ Dextreme Max system is designed to cut excavator energy consumption by up to 50% by reducing energy losses and recovering energy that would otherwise be wasted. An integral component of the Dextreme Max system is the DDP1x0D, a Digital Displacement hydraulic pump that enables energy recovery from excavator motions such as slew deceleration and boom lowering. Danfoss will integrate the DDP1x0D pump and other components required for the new system architecture into a battery-electric excavator.

Danfoss plans to convert a 30-ton electric excavator at its Application Development Center in Nordborg, Denmark, beginning in January 2024. The excavator will then be shipped to and operated at a quarry in the U.K., with project completion planned for February 2025.

The project’s goals are to demonstrate that by improving excavator efficiency, the Dextreme Max system can:

  • Reduce battery capacity requirement from 3 packs to 2 packs
  • Reduce electrical load on charging infrastructure
  • Lower overall capital and operating expenses compared to baseline electric machine
  • Lower total cost of ownership compared to diesel machine
  • Offer the same or better productivity and run time than baseline machines

“This project is an incredible opportunity to prove the efficacy of a new system solution and architecture, demonstrating that large-scale innovation is still possible in hydraulics,” said Jeff Herrin, SVP of research, development, and engineering at Danfoss Power Solutions, in a statement. In addition to the project’s stated goals, we intend to highlight how our application know-how and sustainable innovation is de-risking the adoption of new technology and supporting our customers in their decarbonization journeys. Transitioning to low- and zero-emission machinery isn’t just good for the environment; it can support the construction industry’s drive for lower costs and higher productivity.”

Source: Danfoss Power Solutions

About the Author

Rod Sutton

I have served as the editorial lead of Construction Equipment magazine and ConstructionEquipment.com since 2001. 

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