With rising global environmental awareness and the advancement of the "Dual Carbon" goal, pure electric rollers are becoming a new favorite in the road construction industry due to their superior environmental performance and energy-saving advantages. Below, we will comprehensively analyze the technical features, environmental and energy-saving advantages, and operating precautions of pure electric rollers to provide professional reference for industry users.
1.1 Zero Emissions and Improved Construction Environment
Pure electric rollers utilize electric power, completely eliminating fuel engines, eliminating exhaust pollution, achieving zero-emission operation, and significantly reducing emissions of harmful substances such as CO₂ and NOₓ, meeting stringent environmental requirements.
1.2 Reduced Noise and Improved Worker Comfort
Compared to traditional fuel-powered equipment, pure electric rollers are quieter and quieter on the construction site, allowing operators to focus on operations while minimizing impact on surrounding residents and the environment.
1.3 Reduced Energy Consumption and Maintenance Costs
The electric drive system's simple structure eliminates complex components such as the fuel and exhaust systems, significantly reducing maintenance requirements and costs. Furthermore, the motor boasts extremely high energy efficiency, far exceeding that of internal combustion engines, reducing energy consumption and enhancing economic efficiency.
1.4 High Operating Efficiency and Strong Adaptability
Thanks to the optimized design that coordinates battery life and motor response, a model equipped with a 15 kWh lithium-ion battery, a 10 kW drive motor, and an 8.5 kW vibration motor can operate around the clock, 8 hours a day. International examples also demonstrate operating efficiency comparable to that of traditional fuel-powered equipment.
1.5 Policy Promotion and Brand Enhancement
Electric construction machinery is a type of equipment encouraged by the government to be clean and low-carbon, offering advantages in policy support, green credit, and subsidies. Furthermore, the use of pure electric rollers can enhance corporate social responsibility awareness and market competitiveness.
Pure electric rollers represent the latest development in compaction machinery. Their core technical features are primarily reflected in the following aspects:
2.1 Powertrain Innovation
Employing high-performance permanent magnet synchronous motors, such as the 50kW motor, delivers high torque and powerful power, enabling the working mechanism to compact materials quickly and effectively. This motor technology not only ensures powerful power output but also enables intelligent and efficient energy management.
2.2 Battery and Charging Technology
Equipped with a super-fast charging function, the battery can be fully charged in just 1-1.5 hours, allowing for 4-6 hours of continuous operation on a single charge, significantly improving operating efficiency and continuity. Some high-end models, such as the XD120EP, utilize a dual-wheel motor design, with separate front and rear wheel vibrations for more uniform compaction.
2.3 Intelligent Control
Equipped with advanced intelligent control systems, such as Lutong Intelligent Matching Optimization Technology, it dynamically monitors temperature and current, providing timely warnings to ensure precise control and accurate compaction. The user interface is intuitive and easy to understand, and the intelligent instrumentation provides real-time, all-round monitoring, reducing operational complexity.
2.4 Structural Design Optimization
By eliminating the complex mechanisms such as the gearbox found in traditional fuel-powered equipment, the structure is relatively simple, significantly reducing the failure rate. For example, the maintenance cost of an electric roller with a 50kW high-power motor is approximately 60% lower than that of a traditional model.
To ensure the maximum efficiency and longevity of pure electric rollers, the following aspects must be considered:
3.1 Rational Charging and Battery Life Planning
Plan your charging schedule based on your operating schedule to avoid power outages. An electric roller equipped with a large-capacity battery can operate continuously for 8 hours. With a daily operation of 3-4 hours, charging with Level 2 AC at night can provide 6-8 hours of power per charge.
3.2 Investing in Infrastructure
Pure electric equipment is highly dependent on charging stations, requiring pre-investment in installing outlets or charging piles. For example, some electric roller development teams in China are considering deploying mobile, self-contained charging units to accommodate remote construction sites.
3.3 Daily Battery and System Maintenance
As a high-value core component, batteries must be maintained, temperature monitored, and periodically inspected in strict accordance with manufacturer recommendations. Details such as sliding contacts, protective measures, and over-discharge prevention must be carefully considered to avoid compromising battery life and safety.
3.4 Operation and Safety Requirements
Operation training is essential, especially mastering electrical operating procedures such as charging safety, battery temperature control, and fault diagnosis to ensure safe operation.
Although electric operation is quieter and exhaust-free, vibration and compaction amplitude are similar to those of traditional equipment. Therefore, attention to operating procedures is still required to ensure compaction quality and equipment stability.
3.5 Comparative Cost Evaluation
Although later operating costs are lower, the initial purchase cost of an electric roller is often 50–100% higher than that of a fuel-powered unit. The return on investment should be evaluated from a lifecycle perspective, taking into account the rapidly declining cost of batteries.
Pure electric rollers, with their unique advantages, demonstrate excellent applicability in a variety of engineering scenarios:
4.1 Municipal Road Construction and Maintenance
They are particularly well-suited for asphalt pavement compaction and road maintenance on newly constructed roads. For example, the XD120EP electric-driven lightweight vibratory roller, with its compact structure, maneuverability, and minimal blind spots, is an ideal choice for municipal maintenance.
4.2 Highway Maintenance
In highway maintenance, they excel in asphalt pavement compaction, effectively compacting thin stabilized soil layers to ensure road smoothness and stability.
4.3 Special Environment Construction
For applications such as backfilling and compacting underground pipelines and cable trenches, and in sports field construction, pure electric rollers' zero emissions and low noise levels make them an irreplaceable choice.
4.4 Working in Narrow Spaces
Some electric rollers with twin steel drums are designed specifically for narrow spaces. With a working mass of 850 kg and an excitation force of 25 kN, they are particularly suitable for compacting areas such as sidewalks, bridges, and parking lots.
In terms of performance, pure electric rollers are comparable to traditional equipment. They offer vibration frequencies of up to 55/67 Hz, excitation forces of 28/41 kN, and a static linear load of 120 N/cm, fully meeting various compaction requirements. Furthermore, the electric drive provides smoother power output and improved compaction uniformity.
To ensure the safe and efficient operation of pure electric rollers, pay special attention to the following points during operation and maintenance:
5.1 Operating Specifications
Qualification Requirements: Operators must undergo professional training and obtain an operator qualification certificate. Untrained personnel are prohibited from operating the equipment to prevent improper parameter settings from affecting compaction performance.
Pre-operation Inspection: Before each use, thoroughly inspect the equipment, including battery charge, brake system, and roller condition, to ensure that all components are functioning properly. Pay special attention to tire pressure and wear, as this directly affects driving stability and compaction quality.
Safe Operation:
Maintain a safe operating radius. Standing or walking within the roller's operating range is strictly prohibited.
When changing direction, turn off the vibration switch and wait until the rollers come to a complete stop before operating.
When rolling on newly constructed roads, roll from the center outward to the sides, keeping a distance of at least 0.5 meters from the edge of the roadbed to prevent collapse.
Handling Special Working Conditions:
When operating on slopes, select the gear in advance. Shifting gears on slopes is prohibited, and coasting in neutral is strictly prohibited when going downhill.
Avoid sudden speed changes, sharp turns, and vibration on the spot on soft surfaces to prevent the roller from getting stuck.
When operating at night, ensure adequate lighting to supplement any insufficient lighting on the equipment itself.
5.2 Maintenance
Battery Management:
Regularly check the battery status and charging system to avoid over-discharge.
When parked for extended periods, maintain a moderate battery charge (40-60% recommended).
Use the manufacturer's designated charging equipment to ensure safe charging.
Daily Maintenance:
Promptly clean any debris from the rollers and keep the compaction surface clean.
Regularly check the electrical system connections to prevent poor contact.
Perform regular maintenance according to the manufacturer's instructions to ensure proper operation of all systems.
Storage Requirements:
After operation, park on a flat, solid surface. Parking on the roadside must be clearly marked.
Before long-term storage, thoroughly clean and treat with rust prevention.
Pure electric rollers represent a green revolution in modern road construction equipment: zero emissions, low noise, and high energy efficiency. Compared to fuel-powered equipment, they offer significant advantages in environmental protection, economical operation, and a positive worksite atmosphere. Pure electric rollers are reshaping the compaction machinery industry with their environmental, energy-saving, and efficient features. As technology matures and infrastructure improves, they are poised to become a major force in future road construction, making significant contributions to green construction and sustainable development. At the same time, appropriate charging planning, infrastructure coordination, safe maintenance, and lifecycle cost assessment are key to ensuring their long-term sustainability.
If you have any operational questions about electric rollers, or want to purchase or customize an electric roller, please contact us. We provide customized services for electric rollers.
