Electrification's Impact on the Off-Highway Industry
Read the whitepaper to discover how electrification is driving sustainability and efficiency in off-highway vehicles across farming, mining, and construction.
Read WhitepaperEngineering Vehicle Electrification and Architectural Integration
Off-highway vehicles are increasingly transitioning from traditional internal combustion engines to advanced electric powertrain systems, driven by evolving emission standards and breakthroughs in battery technologies. This shift demands a holistic approach to vehicle architecture, ensuring optimal performance, safety, and regulatory compliance. Tata Elxsi leverages deep domain expertise to deliver end-to-end electrification solutions, covering ECU consolidation, HILS validation, and renewable energy integration.
Through cutting-edge design and engineering, we help manufacturers reduce costs, enhance reliability, and expedite time-to-market.By combining proven engineering practices with digital innovation, our solutions address the challenges of battery system size, weight, and complexity. We empower you to build safer, cleaner, and more efficient off-highway vehicles.
Designing an Integrated Power Combo Unit for EVs
Business Opportunities
Increasingly, digital integration with powertrain technologies is critical to addressing environmental imperatives. We provide end-to-end ownership for EV systems—encompassing concept design, hardware/software engineering, mechanical integration, and BMS development. With ready-to-use HILS frameworks, we reduce validation costs by 40–50%, while ensuring agile system, component, and vehicle-level scalability. Our approach includes supplier interaction, intuitive charging solutions, and CAE-based design validation for robust production readiness.
Here’s How We Help
Battery-Centric Design and Development
- Design and validate battery packs for optimum energy density and durability
- Develop intelligent Battery Management Systems ensuring efficient charging, longer life, and robust thermal management
Integrated ECU and Software Solutions
- Optimize vehicle electronics through ECU consolidation, reducing hardware complexity and cost
- Implement safety-compliant software for advanced diagnostics, predictive maintenance, and seamless user experience
Validation and Testing Frameworks
- Employ scalable HILS setups to validate system and component-level performance
- Leverage simulation-driven approaches to accelerate prototyping and reduce development timelines
Service Framework
Envision a modular diagram illustrating battery pack design, ECU consolidation, and HILS validation at the core. Surrounding these pillars are collaborative processes for concept design, mechanical integration, and production support. This unified framework streamlines workflow, aligns stakeholder objectives, and ensures consistent quality checks—from initial conceptualization to final testing and deployment for off-highway electrification. It guarantees efficiency, scalability, and regulatory compliance.
Intuitive Battery Pack Architecture
Envision a modular diagram illustrating battery pack design, ECU consolidation, and HILS validation at the core. Surrounding these pillars are collaborative processes for concept design, mechanical integration, and production support. This unified framework streamlines workflow, aligns stakeholder objectives, and ensures consistent quality checks—from initial conceptualization to final testing and deployment for off-highway electrification. It guarantees efficiency, scalability, and regulatory compliance.
ECU Consolidation & Integration
Streamline electronic control units by merging multiple functionalities into fewer, high-performance modules. This approach eliminates redundant hardware, reduces system weight, and minimizes wiring complexity. It also ensures consistent communication protocols across all components for improved reliability. Our scalable architecture adapts to evolving off-highway requirements while cutting costs and development time.
HILS-Driven Validation & Testing
Adopt comprehensive Hardware-in-the-Loop systems to simulate real-world operating conditions before physical prototyping. Our modular HILS architecture tests each subsystem—battery, ECU, and power converters—under variable loads, climate extremes, and fault scenarios. This iterative process accelerates quality assurance, resolves potential issues early, and maintains compliance with off-highway vehicle standards and safety benchmarks.
Why Tata Elxsi?
- Proven domain expertise ensuring robust electrification strategies for diverse off-highway applications and global development phases.
- Seamless end-to-end solutions leveraging ECU consolidation, battery design, and advanced HILS validation processes globally recognized.
- Deep collaboration with OEMs for faster prototyping, compliance readiness, and continuous performance improvements across lifecycles.
- Adaptive engagement models carefully tailored to project scope, budget constraints, and evolving industry safety regulations.
- Holistic approach bridging digital and mechanical engineering for scalable, future-proof off-highway electrification high-impact solutions worldwide.
Information Hub
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How is off-highway vehicle electrification shaping the future of heavy machinery?
Off-highway electrification is transforming heavy machinery by significantly reducing greenhouse gas emissions, operating costs, and noise pollution. With improved battery technologies, these vehicles now achieve extended run times and greater power output. Incorporating electric powertrain systems also enables advanced automation and connected services, ushering in safer and more efficient work environments. Moreover, electrification aligns with global sustainability goals, making it a strategic imperative for manufacturers. From construction to agriculture, pioneering off-highway sectors are fast adopting electric systems, leveraging real-time data analytics to streamline operations, enhance reliability, and meet strict emission standards for a cleaner, more productive future.
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What role do advanced battery technologies play in improving vehicle performance?
Advanced battery technologies significantly increase energy density, lifespan, and charging efficiency. By implementing robust Battery Management Systems, manufacturers can optimize charging cycles, effectively manage thermal loads, and mitigate risks such as cell imbalance or overheating. This directly translates to longer operational cycles and reduced downtime. Additionally, improved battery designs lower overall vehicle weight, allowing for increased payload and better maneuverability. Emerging solutions, like solid-state or fast-charge lithium-ion cells, offer enhanced safety profiles and shorter charging intervals, making them ideal for heavy-duty off-highway applications that demand uninterrupted performance, environmental compliance, and cost-effectiveness.
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How does ECU consolidation benefit off-highway electrification projects?
ECU consolidation merges multiple control functions into fewer, high-capacity units, significantly reducing hardware redundancies and wiring complexity. This streamlined approach increases reliability by minimizing potential failure points and ensuring cohesive communication protocols among all vehicle systems. Consolidated ECUs also reduce power consumption, yielding better battery utilization in electric setups. Beyond cost benefits, centralized control modules simplify software updates, supporting over-the-air enhancements and predictive maintenance capabilities. For off-highway vehicles where durability and system integrity are paramount, ECU consolidation accelerates troubleshooting, enables real-time data analytics, and lays the foundation for scalable, future-ready electrification architectures.
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Why is HILS validation critical for off-highway applications?
Hardware-in-the-Loop (HILS) validation simulates real-world operating conditions in a controlled environment, enabling comprehensive testing without costly physical prototypes. For off-highway vehicles facing harsh terrains, variable loads, and extreme climates, HILS ensures each subsystem’s resilience and performance before integration. This iterative process rapidly identifies potential issues in battery management, ECU logic, or power converters, reducing rework and accelerating development timelines. It also supports regulatory compliance by demonstrating robust safety features under simulated stress scenarios. HILS validation is, therefore, invaluable for de-risking complex electrification projects, enhancing reliability, and optimizing total cost of ownership.
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How can Tata Elxsi support OEMs with evolving emission standards and regulations?
Tata Elxsi stays abreast of changing emission standards, collaborating closely with regulatory bodies, industry partners, and OEMs. We offer end-to-end support—covering concept design, battery configuration, ECU software compliance, and HILS validation—ensuring each electrification project meets or surpasses mandated requirements. Our integrated engineering services factor in diverse operational conditions and global certification protocols, mitigating risks of non-compliance. By proactively aligning our solutions with new guidelines and providing continuous validation, Tata Elxsi empowers OEMs to pivot quickly, maintain competitive advantage, and deliver environmentally responsible off-highway vehicles that satisfy both performance benchmarks and regulatory obligations.
