RECOM: Rugged DC/DC Converters for Stable Performance in Off-Highway Electric Vehicles
Power Supplies I 09.04.2025
Off-highway electric vehicles (EVs), such as forklifts and construction machinery, must operate under extreme environmental conditions. To ensure smooth operation, a reliable power supply is essential—one that can withstand vibrations, dust, moisture, and temperature fluctuations.
Figure 1: The RMOD family of DC/DC converters is optimized for e-mobility applications. Even off-highway vehicles can be reliably electrified using these rugged converters. (Source: RECOM)
What requirements do DC/DC converters face in modern industrial and off-highway electric vehicles?
The application areas for material handling vehicles are undergoing constant change. This shift is driven by the trend toward autonomous machines and increasingly stringent emission regulations. In addition to electric applications like golf carts, heavy-duty applications such as forklifts or construction and mining equipment are now also being electrified—posing particular challenges for manufacturers.
These off-highway EVs face demanding operating conditions: not only temperature changes but also strong vibrations, dust, humidity, and electrical stress. At the same time, providing a reliable power supply and connecting high-voltage batteries to the low-voltage components of the vehicle's electrical system is a unique challenge.
For such e-mobility applications, a DC/DC converter is recommended that meets the following key requirements: regulated output, galvanic isolation, and the ability to deliver full performance across a wide input voltage range. It must also be mechanically rugged, operate over an extended temperature range, and comply with relevant IP protection ratings.
Figure 2: A typical power architecture for an e-mobility application (Source: RECOM)
IP Ratings (Ingress Protection) are industry-standard classifications that specify the level of protection against solids and liquids. The IPxx rating consists of two independent numbers that indicate the lev
How does the RECOM RMOD series provide reliable power for off-highway electric vehicles?
RECOM has designed its RMOD series of DC/DC converters specifically for off-highway electric vehicle applications. These converters supply the vehicle's low-voltage electrical system with energy from the high-voltage traction battery. The product line includes variants with power outputs of 300 W, 400 W, and two 600 W models.
The RMOD600-W model features a 24 V output and a wide continuous input range of 33.6 V to 96 V (up to 125 V for 5 minutes). The RMOD600-EW offers a 13 V output and an even wider input range from 33.6 V to 125 V. Both models operate with input voltages down to 24 V for up to 5 minutes. All members of the RMOD family provide isolation up to 2.5 kVDC and are certified to IED/DE/UL/CSA62368-1. They are designed for PCB cooling and can operate at ambient temperatures up to 85°C without derating.
Key benefits of the RMOD series:
Comprehensive environmental protection: Rugged, compact enclosures are sealed to IP67/IP69K standards against dust and water ingress. They are certified to DE60068 for resistance to temperature cycling, shock, humidity/heat, vibration, mechanical impact, and salt spray.
Wide input voltage range: The series accommodates systems powered by nominal 24 V to 96 V batteries, thanks to a maximum input voltage of up to 120 VDC.
High reliability: Delivers up to 600 W of power with galvanic isolation at 2.5 kVDC.
Thermal efficiency: Designed for chassis mounting anywhere on the vehicle, allowing for passive, fanless cooling.
With their rugged design and high efficiency of up to 91.5%, these converters ensure a stable and safe power supply for the onboard systems of off-highway electric vehicles. The RMOD series enhances operational reliability, extends system lifespan, and reduces maintenance—even under the toughest conditions—making them the ideal solution for off-highway applications in construction, mining, and logistics.
At Schukat
We offer power supplies from RECOM and other manufacturers. Also we stock around 6000 different types of power supplies and DC/DC converters in production quantities at our automated central warehouse in Monheim am Rhein, Germany.
We also provide fast, competent support with direct contact persons, and also offer an expert field service team for on-site problem solving. Customers benefit from rapid processing of enquiries, availability of data sheets and samples, and variable delivery quantities – from samples to series production.