Maximizing Operational Flexibility with Swappable Powertrain Technology in Off-Highway Equipment

HeavyTech Inc. introduces a modular and swappable powertrain platform engineered for hybrid and electric compact construction machinery. This whitepaper explores the technological innovation, design philosophy, and operational advantages of our scalable powertrain system, tailored for construction contractors and fleet operators who face varying job site requirements, regulatory demands, and cost sensitivity.

1. Introduction: The Changing Landscape of Construction Equipment Off-highway equipment is undergoing a critical transformation. Environmental regulations, urban emissions mandates, and total cost of ownership (TCO) considerations are pushing operators toward hybridization and electrification. Yet many are met with the challenge of balancing upfront cost with operational reliability, energy availability on-site, and machine versatility. HeavyTech’s swappable powertrain system is a response to these industry-wide challenges.

2. System Architecture Overview Our powertrain platform is designed as a modular subassembly, integrating:

• A universal mounting interface for both battery-electric and hybrid drive systems

• Standardized connectors for electrical, hydraulic, and control signals

• Plug-and-play firmware compatibility between configurations

• Swappable control logic through our purpose built RTOS (real-time operating system) framework

Each machine chassis—whether it be our HT-1 Mini Excavator, HT-2 Compact Track Loader, or HT-3 Compact Articulated Loader—can accept either powertrain module in under 20 minutes using standard shop equipment.

The HeavyTech powertrain

3. Technical Description

3.1 Mechanical Interface

The mounting system is built with precision-machined steel brackets, vibration-damping couplers, and a locating pin geometry to ensure accurate installation and repeatability. Both powertrain variants—Battery Electric Vehicle (BEV) and Hybrid Electric Vehicle (HEV)—share the same mounting envelope.

3.2 Electrical Integration

A unified power distribution unit (PDU) routes high-voltage and low-voltage lines through a central sealed interface. This allows BEV modules to connect to their onboard lithium-ion battery arrays, while HEV modules interface with combustion engines and high-efficiency alternators. The motor controllers and inverters are based on TI C2000 MCUs for deterministic real-time operation.

3.3 Control Architecture

Our real-time control system, built on a custom RTOS for TMS570 microcontrollers, allows dynamic load sharing, safety protocol enforcement, and telemetry feedback. This ensures consistent performance regardless of power source.

Hybrid Genset can be removed quickly due to the unique chassis design that allows wide open access to the compartment.

4. Operational Use Cases

4.1 Urban Job Sites

In noise-sensitive or emissions-regulated zones, operators can quickly deploy the BEV powertrain, benefiting from silent operation and compliance with Tier 5-equivalent mandates.

4.2 Remote or High-Utilization Sites

For longer duty cycles or areas with limited charging infrastructure, the hybrid system offers extended runtime with diesel/gasoline recharging and regenerative braking.

4.3 Fleet Optimization

Contractors managing diverse projects can standardize their fleet on a single chassis type, reducing maintenance training, spare parts inventory, and complexity—while selecting the powertrain module best suited to each job.

5. Economic Impact

Our cost modeling shows that by utilizing swappable modules:

• Contractors can reduce capital expenditure by 20–30% per unit lifecycle

• Downtime between jobs is reduced by 15–40%, due to flexible readiness

• Total fleet energy cost can drop by 25–75%, depending on powertrain usage ratios

The system enables a "pay-as-you-go" style adoption of electrification, aligning with job-specific return on investment (ROI).

6. Manufacturing and Supply Chain Strategy

HeavyTech has developed this solution with a U.S.-first manufacturing mindset:

• Chassis and powertrain modules are fabricated and assembled in Fort Wayne, Indiana

• Power electronics and enclosures are sourced from Midwest suppliers

• Steel and structural parts are formed and welded in Indiana and Ohio

Where global parts are necessary, we ensure redundant sourcing and stringent supplier vetting to minimize risk.

7. Environmental and Sustainability Benefits

Swappable powertrains allow a stepwise migration to full electrification. Our hybrid modules achieve up to 50%+ fuel savings compared to conventional systems. The BEV modules produce zero tailpipe emissions and noise, ideal for urban redevelopment projects.

By enabling modular reuse and refurbishment, we extend the lifecycle of both the vehicle chassis and the energy systems—further minimizing waste and embedded emissions.

8. Competitive Analysis

Most incumbent OEMs either offer fully-electric models with high cost and fixed architecture, or traditional ICE models with no upgrade path. Our swappable platform differentiates by:

• Offering dual-mode operability without dual fleets

• Reducing risk by isolating drivetrain decisions from chassis investments

• Enabling a future-forward pathway with minimal disruption

9. Strategic Vision

Our goal is to redefine the standard for compact construction machinery by proving that electrification and performance can coexist. We envision a scalable ecosystem of interchangeable modules—eventually extending to attachments, operator stations, and autonomy modules.

10. Conclusion

HeavyTech’s swappable powertrain technology empowers contractors and fleet managers to embrace innovation without compromising uptime, budget, or performance. It’s not just a drivetrain—it’s a platform for the next generation of adaptable, sustainable off-highway machinery.

Learn More

Visit heavytech.ai to explore our machines, powertrain options, and how to get involved as an early partner or investor.

For technical inquiries or to request a system demo, please contact engineering@goheavytech.com