Electrification of Construction Equipment Is Advancing Rapidly
The electrification of construction machinery is progressing quickly, but battery capacity and operating time remain some of the industry’s biggest challenges. With Dextreme Max, Danfoss has developed a solution that dramatically reduces energy consumption in excavators while simultaneously increasing machine productivity.
During an extensive development project, Dextreme Max was tested in a 30-ton battery-electric excavator. The results showed that the system reduced energy consumption by 35% over a representative duty cycle. This translates into a 53% longer operating time using the same battery capacity.
How Dextreme Max Works
At the core of the system is Danfoss Digital Displacement® technology, an advanced hydraulic pump/motor with multiple individually controlled outlets. Unlike traditional hydraulic systems, Dextreme Max can:
- Eliminate energy losses during flow distribution.
- Supply each function individually with the exact amount of energy required.
- Recover energy from boom lowering and other overrunning loads.
- Optimize the interaction between the hydraulic system and the electric drivetrain.
By reducing energy losses while recovering energy that would otherwise be wasted, Danfoss states that the system can reduce energy demand by up to 50% in certain applications.
Impressive Test Results
During grading and loading operations, significant energy savings were achieved:
- 49.2% lower energy consumption during grading work.
- 31% lower energy consumption during digging and dumping cycles.
- 35% lower overall energy consumption across a typical duty cycle.
- 53% longer operating time between charges.
The results demonstrate that electric excavators can become significantly more competitive with diesel-powered machines, both from productivity and cost perspectives.
Contributing to the Future of Sustainable Construction Equipment
Dextreme Max was developed as part of a UK innovation program aimed at reducing dependence on fossil fuels within the construction sector. The technology has the potential to reduce the need for large battery packs, lower charging costs, and decrease the environmental impact of construction machinery.
For contractors, this means longer operating periods, lower energy costs, and improved total cost of ownership—without compromising performance.
