Malwa 560C: Electric Powertrain Innovation

Direct-Drive Electric Transmission Improves Efficiency

A key innovation lies in the machine’s transmissionredesign:

• Electric motor directly coupled to the mechanical gearbox
• Elimination of hydrostatic transmission losses
• Reduced energy conversion steps

This architecture offers clear advantages:

• Higher drivetrain efficiency due to fewer losses
• Instant torque delivery for precise low-speed control
• Simplified system design with fewer hydraulic dependencies

This shift illustrates how off-highway vehicle electrification can enhance both performance and system reliability.

Electrified Hydraulics Enable Smarter Power Management

The Malwa 560C retains its hydraulic capabilities but replaces the diesel-driven pump with an electric solution:

• Load-sensing variable pump powered by an electric motor
• Speed control based on real-time demand
• Reduced unnecessary energy consumption

The result is a more efficient electric hydraulic system, where power is only used when needed – lowering both battery usage and acoustic output.

Modular Battery System Supports Flexibility

The machine integrates a scalable battery architecture designed for industrial use:

• 80V cassette battery system with 33 kWh capacity
• 30 kW continuous and 60 kW peak power
• Additional 8.5 kWh embedded battery for extended operation

This modular approach enables to:

• Adapt energy capacity to specific machine applications
• Optimize the balance between runtime, weight, and cost
• Standardize electrification platforms across product lines

Simulation-Driven Engineering Accelerates Development

To meet tight project timelines, engineers implemented early-stage system simulations:

• Digital models of batteries, motors, and controllers
• Evaluation of multiple load scenarios before prototyping
• Validation of system performance and sizing

As illustrated by the simulation visuals below, this approach provided actionable insights into real-world machine behaviour, reducing development risk and accelerating time-to-market.

The electric powertrain was developed as a stand-alone subsystem and integrated via CAN into the machine’s existing IQAN control system.

Collaborative Innovation Enables Rapid Deployment

The project was developed as a Vinnova-funded initiative in Sweden, bringing together RISE (Reserach Institutes of Sweden) and multiple partners to advance OEM electrification solutions.

Regal contributed with:

• System design
• Component integration
• Electric drive expertise

The result was a fully operational electric machine developed within months and showcased at the Elmia Wood fair in 2022 – demonstrating the speed at which electrification projects can now move from concept to reality.

Malwa 560C paves the way for electric work vehicles

The Malwa 560C case confirms that electric drivetrains for industrial vehicles are no longer experimental – they are practical, scalable, and ready for deployment. By combining direct-drive efficiency, electrified hydraulics, modular batteries, and simulation-driven development, OEMs can achieve measurable gains in performance, sustainability, and system control.

Would you like to know how your machines can benefit from advanced electrification solutions?

Explore how your machines can benefit from advanced electrification solutions. Contact our experts to simulate your application and define the optimal electric drivetrain architecture.

Explore Further

• Delve deeper into the project: Electric forestry and agricultural machinery
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• Explore our complete system solution: Electrohydraulic systems