Tag Archives: Dana

Dana debuts new Spicer Electrified e-Powershift transmission at MINExpo 2021

Dana Inc has debuted the new Spicer Electrified™ e-Powershift transmission, a modular and flexible two-speed solution that offers power take-off (PTO) functionality for electrified heavy-duty mining vehicles, at MINExpo 2021 in Las Vegas.

Delivering high efficiency and superior performance in a compact package that simplifies the mining industry’s transition to electrification, the dual-motor version of the e-Powershift transmission supports continuous power outputs up to 240 kW, while the single-motor configuration is engineered for 120 kW of continuous output, the company says.

Its flexible, power-dense design makes it ideal for a wide range of applications, including small- to medium-sized loaders and trucks used in underground mining, as well as construction wheel loaders, large lift trucks and terminal tractors, the company says. The highly efficient dual-motor configuration shown at MINExpo delivers the optimal tractive effort in every duty cycle without torque interruption, according to Dana.

The Spicer Electrified e-Powershift transmission will be available for prototype testing by OEMs by the end of this year.

“For more than half a century, Dana has been a trusted top-tier supplier of drive systems that deliver superior performance for mining vehicles,”  Jeroen Decleer, Senior Vice President, Off-Highway Drive and Motion Systems for Dana Incorporated, says. “The new e-Powershift transmission showcases how we are leveraging our comprehensive portfolio of electrification technologies to provide mining OEMs with complete solutions that can help accelerate their journeys to e-Mobility.”

The launch of the Spicer Electrified e-Powershift transmission demonstrates how Dana is rapidly and effectively developing market-ready solutions that can help streamline and accelerate the mining industry’s transition to electrification, it says.

It is equipped with Dana TM4 high-voltage motors from 350 to 800 v to improve efficiency, reduce total package size and provide redundancy as needed. The motors have delivered field-proven performance and durability for hundreds of thousands of hours in underground mining and other heavy-duty applications, according to the company.

The e-Powershift transmission offers highly efficient shifting through a patented wet clutch and synchroniser, and it can be configured with four-wheel-drive disconnect and a PTO that eliminates the need for an additional motor and inverter, Dana explained.

The system is an efficient turnkey solution, with drivetrain integration simplified through the use of a single APC transmission control unit. It uses proprietary software engineered to optimise machine operation through numerous drive and PTO modes, including hill-hold and functional safety readiness.

The e-Powershift transmission is being shown as part of a complete system that includes heavy-duty Spicer® axles engineered to withstand the most severe mining environments while offering superior braking power for reliability under full load conditions on all operating grades. The system also includes Spicer driveshafts designed for longer life, minimal maintenance and lower operating costs.

The company also announced upgrades to its line of Brevini™ helical and bevel helical gearboxes used in mining and bulk material handling applications, with the new solutions available starting in early 2022.

The enhancements include three new monoblock models to more precisely address torque demands, as well as series-wide design enhancements that improve power density, the company says.

Offering nominal output torques up to 1,000 kNm, Brevini helical and bevel helical gearboxes provide the modularity and flexibility needed to optimise the performance of conveyors, stacker reclaimers, wagon tipplers, and ship loading and unloading equipment used in mining and bulk material handling, it says.

New GHH 45 t capacity dump truck about to enter underground market

GHH has developed a new 42 t payload dump truck that, it says, offers maximum drive power, improved turning radius, steep dumping angle and excellent ergonomics and safety.

The German manufacturer of heavy machinery for civil engineering, tunnelling and mining, which has roots that go back to 1758, has three other underground dump trucks in its underground mining portfolio (in addition to two within its low profile dump truck offering and one within its flameproof portfolio) spanning 15-35 t payload applications. The new truck is the largest in its portfolio.

The new MK-42 offers an up to 45 t payload, 19-24 m³ dump body capacity, maximum drive power, a great turning radius, improved dumping angle and excellent ergonomics and safety, according to the company. It has a streamlined, innovative product design, which just received the Red Dot Design Award, GHH added.

The 460 kW Mercedes OM473 forms the engine base, fulfilling the latest EU Stage V emission standards. GHH also offers Tier 3 and 4 versions for less regulated markets, while an alternative Volvo Penta TAD1651 or 1671 engine option is available.

The vehicle rests on Kessler axles with oscillating articulation and front axle suspension, while the power is transmitted by a converter and gearbox combination from the Dana 8000 series.

Designed for use in harsh environments, especially in underground hard-rock mining applications, the MK-42’s dimensions are surprisingly compact at 3,062 x 10,535 x 2,719 mm (WxLxH). A steep dumping angle of 68° leads to high efficiency productivity and improved cycle time, according to GHH.

The company said special emphasis was placed on a safe and simple design, with low maintenance and repair costs, and operator safety and comfort kept in mind through the entire design process. The ROPS/FOPS certified cab is ergonomically designed to be spacious, quiet, pressurised and effectively air-conditioned to ensure maximum operator comfort while minimising fatigue, GHH says. The strategically placed trainer seat, meanwhile, provides for effective operator training.

The new MK-42 fits seamlessly into the manufacturer’s range of dump trucks and is the perfect haulage partner for GHH’s LF-14 loader, with the combination of the two offering three pass loading, GHH said. Extensive consulting, aftermarket support, parts sales and technical training are just a few of the services GHH offers to all customers worldwide.

Global sales will start shortly as the prototype truck enters its final stage of rigorous testing, GHH said, which added that a special version, the MK-A45, will be marketed exclusively for the Russia market.

Dana builds out China electrification capabilities

Dana has added five facilities in China since the start of 2019 as it looks to strengthen the company’s capabilities for electrification and hybridisation across several markets, including the off-highway sector, throughout the region.

The expansion is the result of Dana’s recent acquisition of the SME Group, as well as the Drive Systems segment of Oerlikon Group, including the Graziano and Fairfield brands, Dana said.

The added facilities expand Dana’s engineering, manufacturing, testing, and aftermarket service in China, and are located in:

  • Shanghai, which engineers and manufactures SME AC electric motors, inverters, controllers, and accessories;
  • Changshu, which produces planetary gear reducers for e-Drives;
  • Baoding, which will make e-Axles for new energy buses, and;
  • Suzhou, one which produces city bus axles; and a second that produces drives, axles, and gears primarily for off-highway mobile equipment and industrial machinery.

Dana’s footprint in China now encompasses more than 6,750 employees at 23 operations, including those in which Dana holds an interest.

Jim Kamsickas, President and CEO of Dana, said: “Dana has been operating in China for more than 25 years and we see a strong opportunity to accelerate our growth in the Asia-Pacific region.

The addition of these facilities shows how Dana will continue to invest in expanding our capabilities for vehicle manufacturers in China – especially for those that are bolstering their electrification initiatives.”

Dana invests in electric hybrid vehicle conversion specialist Hyliion

Dana has entered into a strategic partnership with Hyliion, which will see the New York-listed company take an equity position as a lead investor in the Class 8 electrification company.

Dana said: “The investment is another step in a cadence of strategic transactions to position Dana as the leader in e-propulsion.”

Under the agreement, Dana will become Hyliion’s source for traditional driveline components, as well as fully integrated e-axles – which include motors, inverters, controls, gearboxes, and thermal-management technologies.

Hyliion, founded in 2015, develops intelligent, electric-hybrid architectures for Class 8 vehicles that can be installed on new trucks or retrofitted on existing trucks. This could, essentially, see it turning a traditional 6×2 truck into a 6×4 hybrid. “The Hyliion 6X4HE features the company’s proprietary machine-learning algorithms and battery technology to optimise fuel savings and vehicle performance for reduced emissions and a better driver experience,” Dana said.

Mark Wallace, President of Dana Commercial Vehicle Driveline Technologies, who will become a member of Hyliion’s board of directors as part of the deal, said: “Dana’s investment in Hyliion continues to expand our growth and leadership in electrification across all vehicle segments and partners us with a front-runner in the hybridisation of Class 8 vehicles for fleets ready to adopt electrified vehicles today.

“Together with Hyliion, we have a unique opportunity to develop long-haul solutions that revolutionise power conveyance and support fleets in meeting their efficiency goals, while simultaneously advancing de-carbonisation efforts.”

With its investment in Hyliion, Dana is positioned to supply customers with complete hybrid systems through Hyliion’s intelligent electric-hybrid controls, proprietary battery technology, and integration capabilities, along with Dana’s offering of Spicer® Electrified e-Axles; TM4® motors, inverters, and power electronics; Long® thermal-management solutions; auxiliary system motors through Dana’s acquisition of SME Group; and traditional Spicer® axles and driveshafts, Dana said.

Thomas Healy, CEO of Hyliion, said: “Dana’s wealth of knowledge and extensive strategic experience in the commercial-vehicle market creates a dynamic combination for our Class 8 hybrid platform. We are excited to be joining forces to offer a go-to-market solution for fleets seeking e-propulsion technologies available today in the Class 8 segment.”

Dana’s established field service specialists will work together with Hyliion’s team to jointly call on fleets throughout North America, Dana said.

Hyliion offers fleets a way to decrease fuel expenses and lower emissions by turning semi-tractors into intelligent electric hybrid vehicles. Its patented technology can be used on new or existing vehicles. Requiring no driver training, Hyliion products reduce fuel consumption, reduce emissions, and provide a positive return to fleets and the environment immediately, Dana said.

Dana shifts Spicer gears for underground LHDs, mining trucks and wheel loaders

Dana has announced the development of the Spicer® TE50 powershift transmission designed for large LHDs, underground mining trucks and wheel loaders.

Engineered for vehicles from 400-600 kW (544-816 hp), the Spicer TE50 transmission offers superior performance through improved fuel efficiency, smoother shifting, more precise vehicle handling, and optimised braking, according to the company. The transmission will launch with vehicle manufacturers in the second half of 2019.

Aziz Aghili, President of Dana Off-Highway Drive and Motion Technologies, said: “As the market for mining and construction vehicles moves toward larger vehicles, demand is growing for advanced technologies that support greater productivity without sacrificing precise handling. The Spicer TE50 transmission delivers a robust solution that meets the performance requirements of heavy-duty, high-power applications that operate under some of the most challenging conditions in the world.”

The Spicer TE50 transmission is engineered to fit within current vehicle design envelopes and is offered with a four- or eight-speed gearbox for optimised shifting ratios. It is available with advanced automatic lockup, which improves fuel efficiency by enabling direct drive even at low speeds, Dana said.

An integrated, automatic retarder reduces brake wear and enables smoother, quieter braking. The new transmission is also equipped with three heavy-duty, auxiliary pump drives.

Visitors to the Bauma fair on April 8-14, will be able to see the new Spicer TE50 transmission and Dana’s other innovations for the mining and construction industries in hall A3, stand 325, as well as an outdoor vehicle demonstration area between halls A4 and A5.

Dana Off-Highway expands electrification offering with launch of new drivetrains

Dana has introduced two new electric drivetrain solutions for off-highway vehicles, including the Spicer® Electrified™ e-Axle and e-Gearbox.

These technologies enable electrified propulsion within established vehicle architectures by leveraging the company’s portfolio of motors, inverters, and controls, Dana said.

“Dana, through numerous organic and inorganic initiatives, has filled out its product portfolio to support the needs of its customers,” the company said. “The company will debut its electrified drivetrain solutions in April at Bauma alongside e-Propulsion technologies from the SME Group, which the company acquired earlier this month. These electrodynamic solutions support customers’ needs for efficiency, manoeuvrability, safety, and overall performance.”

Aziz Aghili, President of Dana Off-Highway Drive and Motion Technologies, said: “Vehicle manufacturers in mining, construction, and other off-highway markets are efficiently transitioning toward electrification, while retaining a large portion of their products in traditional technologies.

“Dana has positioned the company to be energy-source agnostic to support our customers across drivetrain configurations, including electrodynamic components that accelerate the adoption of electrification through the introduction of technologies specifically selected to meet the needs of current vehicle architectures.”

The Spicer Electrified e-Axle combines Dana’s heavy-axle design with a high-efficiency TM4 SUMO™ HP motor/generator and inverter combination for medium-sized mining trucks, medium-sized load haul dumpers, and large lift trucks.

Supplying 139 kW of continuous power and 193 kW at peak power, the TM4 motor/generator and inverter are joined at the centre housing of the axle to provide needed torque and efficiency within the space typically allotted for an internal-combustion engine and transmission.

The Spicer Electrified e-Gearbox features a compact design that manages high input speeds and accommodates the installation of an electric motor. “It offers a highly engineered interface for connecting cost-effective motors used in electrification with conventional Spicer hydrostatic transmissions,” Dana said.

Its plug-and-play design combines Dana-supplied TM4 and SME electric motors with Spicer hydrostatic transmissions for small- and medium-sized wheel loaders up to 10 ts and telehandlers with lift capacities up to 6.8 t.

The e-Gearbox will be available for customer testing in the second half of 2019.

Dana said: “The electrified propulsion technologies shown by Dana at Bauma (stand A3 325) will reflect the series of strategic moves made by the company to support electrification and hybridisation in the off-highway market over the past two years, including:

  • “The acquisition of the power-transmission and fluid power businesses of Brevini;
  • “The acquisition of a majority stake in TM4, a manufacturer of high-voltage electric motors, power inverters, and control systems;
  • “An agreement to purchase the Drive Systems segment of the Oerlikon Group, and;
  • “The acquisition of the SME Group, a designer and manufacturer of low-voltage motors and inverters.”

Combined with the company’s expertise in driveline technologies, sealing systems, and thermal management, these initiatives position Dana as the leading supplier of electrification solutions for the off-highway segment, the company said.

Dana shows off Spicer Electrified with TM4 e-Hub Drive at Bauma China

Dana Incorporated has introduced the Spicer® Electrified™ with TM4® e-Hub Drive at the Bauma China show this week.

This fully integrated electro-mechanical system for heavy-duty mining and construction applications leverages Dana’s portfolio of vehicle electrification technologies, according to the company.

“Designed for underground mining trucks, large wheel loaders, and reach stackers, this e-Hub drive integrates proven heavy-duty Spicer axle expertise, Brevini® planetary drive designs, TM4 electric motor technology, and Dana’s advanced control expertise into a single package that delivers efficiency, reliability, and performance,” Dana said.

Currently in pre-production field testing with vehicle manufacturers, the e-Hub drive is scheduled to be ready for production by the end of next year.

Christophe Dominiak, Chief Technology Officer for Dana, said: “The ultimate measure of hybrid and electric technologies is their ability to meet the rigorous performance expectations of off-highway vehicles at the work site.

“This e-Hub drive illustrates how rapidly and effectively Dana has capitalised on our strategy to produce hybrid and electric propulsion solutions that perform in the harshest work environments anywhere in the world.”

Dana’s global centre of excellence for designing axles used in mining and other heavy-duty applications, the Dana China Technical Center in Wuxi, Jiangsu province, is ideally suited to lead the development of the e-Hub drive, the company said.

“The facility also leads the development of heavy-duty Spicer planetary steering axles for rough-terrain cranes with lift capacities ranging from 30 t to 110 t.

Dana’s engineering resources in the US, Italy, and Canada participated in the co-development of the Spicer Electrified e-Hub Drive, the company said.

Aziz Aghili, Executive Vice President of Dana and President of Off-Highway Drive and Motion Technologies, said: “With 23 worldwide technology centres strategically located near our customers, Dana has a distinct advantage in the development of propulsion systems for heavy-duty vehicles.”

“By combining our unmatched range of technologies with our regional expertise, Dana can precisely channel our engineering efforts toward highly tailored solutions on a market-by-market basis.”

Dana has emphasised engineering and development for hybridisation and electrification as part of the company’s enterprise strategy, which focuses on leveraging its decades of electric engineering expertise and product knowledge to offer an extensive portfolio of advanced hybrid and electric technologies that have been engineered for multiple vehicle markets.

“Ranging from complete systems and modular solutions to individual sub-system components, Dana is able to support its customers in developing series and parallel hybrid configurations up to full battery-electric vehicles.

“Dana’s electrified product offerings are able to meet the diverse architecture and platform requirements of its broad customer base by delivering enhanced performance, packaging optimisation, and reduced system weight,” the company said.

Dana has made a series of strategic moves to support electrification and hybridisation, including the acquisition of the power-transmission and fluid power businesses of Brevini; a majority ownership of TM4 Inc, a motor and inverter manufacturer; and an agreement to purchase the Drive Systems segment of the Oerlikon Group.

“Combined with the company’s core expertise in driveline technologies, sealing systems, and thermal management, these initiatives position Dana as the leading supplier of electrification solutions for the off-highway segment,” Dana said.

With the recent acquisition of TM4, Dana’s electrification capabilities now include in-house design and manufacturing for electric motors, power inverters, and control systems. Dana also offers a wide selection of Brevini® motion products to support the power distribution requirements of hybrid and electric off-highway vehicles. These products include gear pumps, hydraulic power units, valves and controls, hydraulic axial piston motors and pumps, orbital motors, control hardware and software, advanced sensor technologies, and operator-information displays.

Beyond the e-Hub drive, Dana is currently leveraging a wide portfolio of technologies for off-highway customers to offer dozens of successful electrified driveline applications now in production and pre-production testing.

Dana’s growing portfolio of electric and hybrid technologies is ideally positioned to support the Chinese Ministry of Industry and Information Technology’s ‘Made in China 2025’ initiative, and the company’s expertise has been honoured by leading organisations, it said.

For four consecutive years, Dana has been recognised by the China Decision Makers Consultancy for its electric and hybrid vehicle solutions. In 2017 and 2018, Dana was named the ‘Outstanding Power Electronics Solution Provider of the Year’, while Dana earned the ‘Best Battery Solution Provider of the Year’ award in 2015 and 2016. Additionally, Dana’s two-sided chip cooling technology was a 2016 Automotive News PACE Award finalist.

Dana serves numerous off-highway manufacturers in China, including AGCO, CRCHI, Epiroc, John Deere, and SANY. The company currently operates 17 facilities in China with approximately 6,750 employees through both wholly owned and joint venture operations.