Solutions for Mobile Machines
eLION: Consistent portfolio for all machine classes
The expanded eLION portfolio enables the consistent electrification of the entire machine fleet. The new elements: eLION Power and Motion Control, highly compact HV motors, and a 96-volt offering for smaller off-highway vehicles.
The advancing electrification of mobile working machines brings the topics of standardization and scalability into focus. How can off-highway manufacturers increase efficiency in development and operation across all machine classes?
1. Software functions for power management, drive system, and working hydraulics
Many OEMs invest heavily in developing their own control software and find the effort in development, integration, and maintenance increases with each electrified model. This doesn't have to be the case. With the eLION Power and Motion Control portfolio, Bosch Rexroth now offers a cost-efficient alternative with a unified software logic across all machine sizes. Whether it's a new development or the conversion of existing vehicles, such as for rental fleets: integration is faster and more reliable with the portfolio specially developed for off-highway applications. At the same time, the complexity of electrification is reduced while optimizing machine performance and ensuring a needs-based operating experience. The solution approach – fitting for the BODAS Ecosystem – is modular and consists of three application software solutions that can be flexibly adapted to various applications:
Electric power control EPC
Controls the high-voltage system, communicates via standardized interfaces with battery and thermal management, and ensures electrical integrity. The integrated Power Management is optimized in terms of functionality and availability.
Travel drive control EDA
Controls the traction drive and enables both speed-based and load-sensing driving. This allows, among other things, the familiar operating feel of a hydrostatic drive to be precisely replicated.
Pump drive control PDC
Integrates the inverter, motors, and pumps with electronic control. In addition to pump control, the application software offers a variety of functions for energy-efficient and low-noise operation.
Conclusion:
The new eLION Power and Motion Control portfolio enables fast time-to-market and reduces development costs through pre-validated functions for high-voltage systems, traction, and pump drives. The portfolio integrates Rexroth eLION components such as inverters, motors, onboard chargers, and DC-DC converters. It allows optimal vehicle control and offers customizable interfaces to battery management and thermal management systems. Market launch began at the end of 2025, and initial pilot projects are already underway.
2. Versatile motors with high power density
Same installation space, with up to 50% more power – that's how simply the new EMP1 motor series can be described. With this expansion, the eLION high-voltage portfolio grows to include a scalable off-highway-optimized motor platform for highly efficient pump drives, traction, and generator applications. The significant increase in power density with substantially higher traction force and lower gear ratios is based on an optimized electromagnetic design. The result: more compact, lighter, and more powerful machines. With five lengths, the scalable high-speed motors cover a continuous power range from 30 to 175 kW and impress with consistently high performance across the entire speed range. This opens design flexibility: every type of drive can be optimally supported – with higher machine efficiency and longer battery life.
3. Standardized 96-Volt portfolio
Many manufacturers consciously begin the transformation with compact machines in the 96-volt range – for example, with wheel loaders or telehandlers. Others are already active in the high-voltage segment and now also want to electrify smaller power classes. That‘s why Bosch Rexroth complements the eLION Power and Motion Control portfolio with a 96-volt offering. This includes motors and inverters with CAN-J1939 communication, UDS diagnostic protocol, and fully integrated functional safety according to ISO13849. Thanks to these standard interfaces, manufacturers of mobile working machines benefit from a consistent communication and diagnostic infrastructure, which also significantly simplifies later scaling to higher voltage classes and power categories.
What transformation challenge are you currently facing?
Contact us! Let's find an efficient and powerful solution together.
info.electrification@boschrexroth.de
The entire eLION portfolio and more information at a glance? www.boschrexroth.com/eLION
Peter Fischbach sales and product management member of the project team off-highway electrification, in the Bosch Rexroth Mobile Solutions business unit. In his professional career, he worked in various positions, including the Rexroth Industry Sector Management for Factory Automation, Application and Product Management and as head of the REFU Elektronik U.S. subsidiary prior of joining the Bosch Group. He has a strong electrical engineering background and 30+ years’ experience in drive power electronics, digitalization/IoT, and electrification in the area mobile applications and factory automation.
Michael Mast sales and product management member of the project team off-highway electrification, in the Bosch Rexroth Mobile Solutions business unit. Here, he works as a Product Manager for application software and systems for electric drives. In his professional career, he has held various positions, including vehicle testing and project management for hydraulic drives in closed and open circuits. He possesses a profound background and over 17 years of experience in hydraulic and electric drive technology, as well as the electrification and control of drives for mobile working machines.
