The construction and mining equipment industries, like many other mobile and industrial sectors, are moving toward ever greater levels of electrification and automation. As such, numerous technologies are being introduced to aid with this transition — many of which will be on display at bauma 2025.
bauma is considered to be the largest international event for the construction and mining industries and therefore an ideal place to showcase the newest developments for creating electric-powered machines and automating their various functions.
Fluid power systems, particularly hydraulics, remain important to the operation of many mobile machines and as such are continuing to be impacted by the electrification and automation developments taking place. In some cases, this includes the replacement of some or even all of the hydraulics on a machine. Thus, seeing what new technologies are coming into play can help the fluid power industry understand how it must continue adapting to these market trends.
In this article you’ll find highlighted a sampling of the new technologies that will be exhibited at bauma 2025 designed to aid with the electrification and automation of off-highway equipment.
Baumer Exhibiting Safety Certified Sensors
Sensor company Baumer intends to show several of its newest sensor technologies designed for mobile equipment applications at bauma 2025, including those which can aid with ever increasing levels of automation.
Among these is the EAM580RS encoder designed to provide a high level of safety, a key requirement for automation. The encoder meets the latest requirements of functional safety (SIL2/PLd according to IEC 61508, ISO 13849:2023 and IEC 61800-5-3). According to the company, this safety certificate will ease and accelerate engineering work as well as parallel system certification since it significantly simplifies additional documentation.
The EAM580RS is a magnetic safety encoder designed to withstand use in harsh operating conditions. It is protected against shock and vibrations while offering fast transmission rates during operation.
Data on revolutions, operating time and input voltage for machine monitoring and many more purposes can be achieved with the EAM580RS.
Comer Presenting Powertrain Components for Electric Machines
Comer Industries will show several recent powertrain technology developments for electric-powered mobile equipment.
A powertrain system for compact electric wheel loaders up to 5 tons is one of the new products that will be shown at bauma 2025. The powertrain consists of a new electric module called eMD1 which directly inputs power into the differential gearbox of the rigid compact axle, removing the traditional dropbox from the driveline. The rotational speed of the motor is reduced by a planetary drive unit and the rotary and torque motion is transferred to the front axle by a constant velocity shaft.
Also on display will be a planetary drive for electric excavators known as the WD300EX Series, an all-in-one integrated electric wheel drive designed for mini excavators. It consists of a planetary gearbox combined with an interior permanent magnet motor and is capable of delivering high torque to meet performance needs throughout the life of the machine.
The WD300EX is equipped with an electromagnetic negative brake that offers an electric, waterproof alternative to hydraulic-powered gearboxes according to Comer.
Liebherr Unveiling New Electric Motor Technology
At bauma 2025, Liebherr-Components will introduce a new permanent magnet electric motor for use in off-highway equipment. The company says the motor offers the same power density as the hydraulic versions typically utilized but eliminates the need for all the hoses and other components associated with hydraulics — helping to minimize overall machine weight as well as design simplicity.
The electric motor features a direct oil-cooled design developed specifically for use in battery- and diesel-electric traction drives. Per Liebherr-Components, this allows for quick and easy installation, as well as the electrification of existing hydraulic drive concepts.
Moderate pressures in the cooling circuit minimize the risk of leaks, improving safety.
A reduced number of gears reduces maintenance while also extending the lifespan of the motor as there are fewer components which could wear over time.
Per the company, the new electric motor also offers improved efficiency compared to hydraulic options. The electric motor has an efficiency of 94-96% while hydraulic motors tend to be in the 50% efficiency range. This will help to reduce energy consumption in electric and hybrid vehicles, leading to longer run times.
Scanreco Introducing New Remote Control and Other Safety Technologies
Scanreco, a developer of remote control and other safety technologies, intends to showcase several of its products aimed at improving operational safety and efficiency. Among these will be proximity detecting features, remote controls with live video streaming, an infrared line of sight feature as well as the company’s line of full-color displays.
With these technologies, machine systems — including those powered by hydraulics — can be controlled or monitored from a safe distance. They also fit in well with the move toward further automation taking place in construction equipment and other mobile machinery applications.
The company plans to introduce several new products at the show such as a proximity detection system which measures the distance between the transmitter and the receiver, ensuring that the operator always stays within a set safe zone. It provides continuous monitoring of the distance between the machine and the operator and is well suited for use with hazardous machines and autonomous operations.
An infrared solution will also be introduced for self-propelled applications such as trench rollers and compactors. This solution creates a line of sight so operators can always observe machine operation.
Scanreco will show its “Smart Operator concept” as well. It is intended to demonstrate how well thought-through remote control design can help operators in their daily work situations. In addition, by taking a thorough design approach creation of intuitive controls which are easy to use and significantly cut the learning curve of the application can be achieved. This helps get new and inexperienced operators up to speed quicker even on complex machines, leading to productivity and safety improvements.
Schaeffler to Show Solutions for More Sustainable and Efficient Machines
Motion technology company Schaeffler will exhibit several technologies aimed at helping create machines which are more sustainable through their use of electrification as well as those designed to improve the efficiency of various machinery.
The electrification of drives and operating functions, and reliance on the consistent use of low-friction rolling bearings and sensors are some of the ways it achieves these sustainability and efficiency goals.
Electric motors will be among the products on display. The company’s electric motor portfolio covers voltage ranges up to 800V to meet the performance needs of heavy-duty equipment. At bauma, the company said a particular highlight will be its electric motors offering a maximum speed of 10,500 rpm and continuous power output of 219 kW.
Also on display will be the company’s line of electromechanical linear actuators which can be used for operating functions as well as the automated operation of flaps and engine hoods. Products in this line cover nominal forces from 1.5-150 kN and travel ranges from 300- 2,000 mm; they can be used in applications such as small excavators, wheel loaders, and mobile work platforms.
Use of electromechanical actuators (also referred to as electric actuators) are gaining ground in some mobile equipment applications in place of hydraulic cylinders due to the precise control they can provide as well as reduced maintenance.
Schaeffler’s tapered roller bearings which will be on display at bauma 2025 feature an optimized rib contact and improved raceway surface structure to reduce friction, leading to efficiency improvements, and maintenance. According to the company, its high-performance bearings can provide significant energy savings when used in the hydraulic motors and pumps of machines such as wheel loaders.
Moog Introducing New Systems to Aid Electrification Design and Use
Moog Construction, part of Moog Inc., and its ZQUIP brand will be showcasing their latest developments for machine electrification and automation at bauma 2025.
At the show it will introduce its Adaptive Electrification Management System which was developed to reduce the cost and complexity of designing, building, operating, and repairing electric off-highway vehicles. The system is part of Moog Construction’s TerraTech portfolio of products that aid in the creation of electric machines; the portfolio is comprised of advanced electronics, configurable software, high-performance electric motors, electric cylinders, and electric motor/pump units.
The Adaptive Electrification Management System simplifies managing multiple functions on electric vehicles. It integrates an advanced controller with configurable software, high-voltage power distribution, DC/DC converters, and both single- and dual-axis inverters to efficiently power multiple machine functions. Reductions in cost and packaging can be achieved through the use of a high-voltage busbar and shared coolant manifold to reduce cables and coolant hoses.
ZQUIP, Moog’s brand focused on developing electrification solutions, will show two new developments at bauma, the first of which is an energy-supply system for zero-emissions vehicles. It can be adapted to power a vehicle on either diesel fuel or battery energy. The company explained that its engineers can equip a diesel-hydraulic machine by removing its diesel engine and installing a modular conversion kit containing one or multiple 1.2-by-0.8-meter power modules. Vehicle owners can then choose the type and amount of energy for their machine, offering them flexibility.
“ZQUIP’s adaptable power exchange means you can run your machine no matter which energy source the world chooses for construction vehicles,” said Rob Bauer, engineering manager for ZQUIP. “A ‘zquipped’ machine can be zero-emissions when required or run diesel to extend its workday. The ZQUIP diesel power module acts as a range extender, keeping battery power modules charged to maximize uptime, effectively creating a hybrid machine.”
ZQUIP will also be showing a prototype 8-ton excavator that is geospatially intelligent and powered by a swappable, zero-emissions battery system. It was developed in collaboration with Leica Geosystems, part of Hexagon.
The excavator is equipped with Leica Geosystems’ advanced machine control solution, which brings real-time data and precise design execution. This technology allows operators to have a better understanding of where the excavator’s bucket is, enabling more optimized machine operation. Machine control systems such as this help to automate operation, leading to increases in production and efficiency as well as safety.
