SUNCAR is pleased to announce its collaboration with Manitowoc, a leading manufacturer in the mobile crane industry, for the market launch of its new GMK5150XLe plug-in hybrid mobile crane. The vehicle combines the best of both worlds – exceptional performance and energy efficiency with lower emissions. Developed to meet the growing demand for sustainable solutions in the crane industry, this hybrid mobile crane represents a major milestone in reducing local CO₂ emissions and offers an environmentally friendly, high-performance alternative.
Key Features
- Hybrid drive: Crane operation is powered exclusively by battery energy, but can be recharged via the diesel engine. The battery capacity is sufficient for an average working day with 2–3 deployments per day.
- Flexible charging options: The crane features AC and DC charging interfaces, and the battery can also be charged via the generator/diesel engine.
- Efficiency gains: Energy recovery during travel and diesel-free mode during crane operation.
- Innovative system integration: Minimal modifications to the crane model, intelligent control, and optimized thermal and energy management.
Project Objectives
The project to electrify crane operations had clear milestones defined in a structured timeline. The preliminary study was completed by the end of September 2023, and the project launched in October 2023. Commissioning of the prototype crane took place in October 2024, followed by a three-month testing phase and further adjustments.
Results
The goal of the project was to electrify the crane’s upper carriage so that it can handle a regular working day purely electrically.
Technical Data
Technical specifications for the upper carriage include a motor that drives the hydraulic pump and a 180 kWh battery. The battery allows for both AC and DC charging, ensuring a flexible energy supply. If required, the crane can be charged during operation via the charger – the so-called “Cable Run” function. The hydraulic drive units are powered by a high-performance electric motor in the upper carriage, which improves hydraulic efficiency through intelligent control. The lower carriage houses a 170 kW generator, a 22 kW AC charger, and a 250 kW DC charging interface.
Efficient Charging and Energy Concept
The charging and energy concept includes charging via the 400 V/32 A power grid, charging during operation, and charging via the onboard generator at up to 1 C. An advantage of the system is the possibility of recuperation during travel and braking, which extends the operating time on battery power. When setting up the crane on-site, it can additionally be charged via the generator, allowing for better utilization of the diesel engine. For typical crane use with 2–3 deployments per working day, the new system thus offers a high degree of efficiency. The battery can be charged at 16 A/32 A at 400 V and allows for self-charging via the generator, achieving a recharge from 5% to 80% in less than one hour. The crane delivers the same performance as the standard GMK5150XL.
Innovative System Integration with Minimal Conversion Effort
System integration is based on a conventional crane model with minimal conversion effort. The electric motor is combined with the existing hydraulic pump. The system’s thermal management is linked to the upper cabin’s air conditioning. The system also includes advanced energy management, specialized control software, and extensive service and maintenance options.
More info: https://www.manitowoc.com/de/grove/at-krane/gmk5150xle
