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Hybrid drive system makes emission-free operation feasible

You are required by the client to work emission-free, but you are concerned about the high costs and limited usability. Then you haven’t spoken yet with Steven de Kam of SDK Diesel Support and SDK Engineering. His company has developed the CHD-e, a hybrid electric drive line that can be installed as a retrofit or in new builds for large construction equipment. A great example is the anchor drilling machine from Hakkers.

As a diesel specialist, Steven de Kam regularly sees companies too quickly and thoughtlessly say goodbye to the reliable diesel engine. This requires them to make huge investments, on the one hand for an expensive full electric machine, and on the other hand because often a very large and costly battery container also needs to be placed next to it. While there is another way by taking a less drastic step in the form of hybrid.

Understanding the customer’s energy demand and then thinking out-of-the-box to meet that demand. That’s Steven in a nutshell. He believes that the customer should mainly focus on their own work and should not also be burdened with drive problems. Steven and his team take care of that part. In short: they have developed a standard product that allows companies to meet the requirement of emission-free operation in an affordable way.

A look inside the battery pack of the CHD-400e for the anchor drilling machine from Hakkers.

Combined Hybrid Drive Electric

This standard product is the Combined Hybrid Drive Electric (CHD-e). It is a drive line based on an electric motor and battery pack. For extra power and reserve time, a backup range extender is used in the form of a small combustion engine. Any type of fuel is possible: from diesel to hydrogen, ethanol, biogas, and so on, making it future proof. The CHD-e can be used emission-free anywhere without compromising on ease of use or operating time.

The CHD-e drive line is distinctive because it can run fully electric, via its own battery pack or connected mains power. If necessary, it can switch to hybrid mode. In this mode, the combustion engine provides extra power and also drives the electric motor and recharges the battery pack. Downtime due to an empty battery pack (one of our biggest fears, as practice shows) or the lack of external mains power is a thing of the past. The hybrid is in fact just as reliable an installation as conventional systems.

The electric CHD-e generator set with 200 kVa (160 ekW) power. The Combined Hybrid Drive uses a 3.6-liter Stage V diesel as backup.

Usable for construction equipment and as a generator

Low noise, environmentally friendly, and reliable are the keywords of the Combined Hybrid Drive Electric. In existing construction machines, it replaces the large diesel engine. Thanks to its compact size, it can almost always be installed. The very low emissions compared to other hybrid solutions are partly due to the smart use of the right components. This also made it possible to build a CHD-e generator set. It comes in two models: the hybrid generator H100/200 and a hydrogen generator H2, both with 200 kVa (160 ekW) power. The difference lies in the engine used: a 3.6-liter Stage V diesel versus a hydrogen engine. Four hybrid generators have already proven themselves as energy suppliers during the repair work on the IJssel bridges on the A12 near Arnhem.

The anchor drilling machine from Hakkers in Werkendam received a retrofit. The existing engine was removed and replaced by a CHD-400e.

Anchor drilling machine as a current example

Hakkers, also from Werkendam, specializes in vibration-free installation of pile foundations, sheet piles, and grout anchors. Among other things, an anchor drilling machine is used for this. Hakkers endorses the Clean and Emission-Free Construction covenant signed at the end of October. It is therefore not surprising that this anchor drilling machine has had a retrofit. The existing engine was removed and replaced by a CHD-400e. This is a fully electric, and thus completely emission-free drive line at the workplace, with a power of 220 kW and a battery capacity of 267 kWh. When the battery pack runs empty, it can be connected to a mains connection for charging. It can also remain continuously connected if desired, allowing for long-term electric operation. As a result, there is no longer any fear of premature downtime.

Steven: “In this way, the best of both worlds is incorporated into this machine. This project was extra special for us because this is the first CHD-e in this application. It passed the test runs with flying colors. The anchors go into the ground without any problems and the best part is, emission-free operation is possible, everywhere!”

Service and engineering

SDK Diesel Support is an internationally active service company specializing in maintenance, repair, and overhaul of Caterpillar engines. Work is carried out with the latest generation, such as stage V, by specialists in aftertreatment, malfunctions, and electronics. The company, based in Werkendam, has been operating in the maritime and industrial sector since 2012, has about 15 full-time employees, and is increasingly working in the industrial sector for service on Caterpillar engines.

SDK engineering is a fairly new department within SDK Diesel Support. This department focuses on the efficient use of available energy sources and has developed, among other things, a hybrid drive line: the Combined Hybrid Drive (CHD). It can replace almost all types of combustion engines in pile drivers, hydraulic power packs, generator sets, power units, water pumps, and so on. And that both in new installations and as a retrofit. The CHD-e is the more advanced new version of the hybrid drive system for large equipment.

The hybrid genset Stage V at the test location, where it quickly became clear that the hybrid drive is in fact just as reliable an installation as conventional.

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