everything PE recently interviewed Daniel Nuttall, Director of Hardware Engineering at Delta-Q Technologies. Delta-Q Technologies specializes in battery charging solutions for electric vehicles and industrial equipment.

Q. Can you provide some information about Delta-Q Technologies? When was the company founded and how has it developed over time?

Daniel Nuttall: Since its founding in 1999, Delta-Q Technologies (Delta-Q) has been at the forefront of electrification for industrial and recreational vehicles, collaborating with top-tier OEMs. Recognizing a gap in the low-power non-automotive electric vehicle market, the company addressed manufacturers’ concerns about the size and weight of existing chargers. As a result, their solution was to design a compact, high-frequency power conversion battery charger inspired by automotive-grade standards, ensuring high durability and making it one of the most rugged and reliable options available in the market.

Delta-Q’s global engagement with electric vehicle and machinery manufacturers revealed a significant demand in the golf industry. After securing its first customer and gaining significant market share in the industry, the company expanded its focus to develop the next generation of battery chargers, targeting new market verticals such as material handling and mobile elevated work platforms (MEWP).

In 2016, ZAPI GROUP - an Italian manufacturer of electronic speed controllers for electric and hybrid vehicles - acquired Delta-Q. As part of ZAPI GROUP, Delta-Q offers a comprehensive range of on-board and off-board battery chargers in collaboration with ZIVAN, a global leader in charging technology for battery-powered vehicles and equipment, headquartered in Italy. The chargers, ranging from 350 W to 36 kW, cater to diverse markets, including material handling, e-mobility, floor care, utility/recreational vehicles (such as electric golf cars), outdoor power equipment, agriculture, and construction. These chargers are designed for integration with other ZAPI GROUP solutions and their battery partner network.

Q. Can you tell us more about your product portfolio? 

Daniel Nuttall: Delta-Q has five product families: the IC Series, XV Series, RC Series, RQ Series, and ICL Series.

Our charging solutions are designed to charge both lead-acid and lithium-ion batteries. Collaborating with top battery and BMS manufacturers, we develop, test, and validate custom charging algorithms to optimize performance and ensure safe charging. Our products undergo rigorous testing for harsh applications to prevent charging failure, and our robust charging software is equipped to identify and address potential charging hazards.

Some of the standard features and benefits of our charging solutions include:

• High Reliability: Delta-Q chargers are validated for an 8-year design life, tested for worst-case operating conditions, and manufactured in a world-class LEAN production facility through our network of manufacturing partners in Asia and North America. 
• Sealed and Rugged: All chargers are constructed with an IP66 and IP67-rated aluminum die-cast enclosure and tested for extreme shock, bump, vibration, humidity, and temperature cycling that you would expect at an automotive-grade level.
• Charge Quality: OEMs can choose from 200+ charging profiles for lithium and lead-acid batteries to optimize charge time, battery life, and application requirements.
• Global Standard Compliance: All chargers comply with North American and European safety and EMC standards (FCC-B and UNECE R10) and touch-safe voltage regulations, allowing easy integration into electric vehicles.
• CAN Bus Communication: Delta-Q chargers use CANopen and J1939 protocols to interact with vehicles, telematics, and lithium BMS, update charger software, load charging profiles, and download charge tracking and diagnostic information.
• Global and Efficient: Delta-Q chargers have a wide AC input voltage range and can operate on any single-phase grid worldwide, meet global energy efficiency standards (i.e., CEC, DOE, and NRCAN) and have high-efficiency performance, enabling electricity savings and shorter charge times.
• Ease of Integration: Delta-Q's battery chargers offer flexible connectivity and software configurability, streamlining integration and configuration for batch production and aftermarket solutions. These chargers adapt seamlessly to various systems, allowing fine-tuning through software settings. Whether in mass production or retrofitting existing vehicles, Delta-Q’s approach ensures efficient and customized charging solutions.
• One Charger: Customers can upload up to 25 charge algorithms for lead-acid or lithium batteries on Delta-Q chargers, and active algorithms can be selected with push-button or CAN bus.

Q. Which market segments do you cater to? Which segment is the largest for you?

Daniel Nuttall: Delta-Q’s battery chargers excel in demanding markets where reliability is critical. We rigorously validate our charging solutions for maximum reliability even in the harshest conditions, ensuring uninterrupted performance. These markets include:

• Outdoor Power Equipment
• Mobile Robotics
• E-Mobility
• Construction
• Agriculture
• Floor Care
• Golf & Utility Vehicles
• Material Handling
• Mobile Elevated Work Platforms

Out of these markets, the largest market segments for Delta-Q Technologies are lift trucks, construction lifts and equipment, utility vehicles, commercial golf cars, and other off-highway e-mobility solutions.

Q. What are the latest advancements in charging technologies offered by Delta-Q? 

Daniel Nuttall: Delta-Q recently introduced two products that cater to the diverse needs of off-highway electric vehicles: the XV3300 and RQ700. Both products represent cutting-edge technology and robust design, addressing the evolving demands of electric vehicle charging infrastructure.

The XV3300 is a versatile 3-in-1 mid-power charging system that is compact, scalable, and reliable. This high-performance 3.3 kW charger features an integrated 500 W DC-DC converter and an Electric Vehicle Supply Equipment (EVSE) interface. These key features are housed in a ruggedized IP66/67 design, offering Original Equipment Manufacturers (OEMs) of off-highway machinery a comprehensive package for simplifying their machines’ electrification. The XV3300 charging solution, available in 58.8 V, 65 V, and 120 V DC models, is scalable, allowing OEMs to stack up to three chargers for power levels up to 10 kW. The 3.3 kW charger employs advanced algorithms to efficiently charge various types of battery chemistries and voltages, extending their lifespan and reducing charge time.

XV3300

The charger’s integrated DC-DC converter provides auxiliary power to operate vehicle accessories such as air-conditioners, controllers, lights, turn signals, navigation, and communication devices. This feature eliminates the need for an external DC-DC converter, saving space and cost for OEMs and equipment operators. The charger complies with both SAE J1772 (levels 1 and 2) and IEC 61851 (modes 2 and 3), enabling it to charge from standard EVSE AC charging stations across North America and Europe. This provides end-users with more charging options and greater vehicle flexibility.

On the other hand, the RQ700 is a compact, rugged, and highly efficient battery charger designed to meet the demanding reliability, durability, and safety conditions similar to automotive environments. This charger redefines quality expectations and customer experience in the low-power battery charger market. It offers 12 V - 400 mA of auxiliary power for the operation of small loads like Battery Management System (BMS) wake-up and telematics, making it well-suited for lithium-ion batteries. The RQ700 also supports Unified Diagnostic Services (UDS) and Controller Area Network (CAN) communication, providing standardized service and upgraded diagnostic tools to meet current market requirements.

RQ700

Q. What makes Delta-Q's charging solutions stand out in the market?

Daniel Nuttall: 

1. Designed to meet strict specifications: Delta-Q’s charging solutions are the product of a rigorous design, fabrication, and testing process that satisfies our customers’ electro-mechanical, performance, and safety specifications while excelling in the harsh operating conditions encountered in daily field operation.
2. Reliable and scalable delivery: With 25+ years of experience supplying high-volume productions to leading electric vehicle OEMs globally, our Lean manufacturing processes allow us to offer scalability and reliability for your projects.
3. A ZAPI GROUP Charging Solution: As part of the ZAPI GROUP, in collaboration with ZIVAN, Delta-Q provides a comprehensive range of on-board and off-board charging solutions from 350 W to 36 kW, tailored to support various leading lead-acid and lithium battery brands and chemistries through our extensive battery partner network. By leveraging the group’s system expertise - including motor controllers, electric motors, battery chargers, and autonomous navigation software for full-electric and hybrid vehicles - we help our customers design efficient electric vehicles that meet their cost goals and comply with stringent environmental standards. Our charging solutions seamlessly integrate with these system components, ensuring a cohesive and reliable performance. Our ability to quickly adapt to the evolving needs of our customers and partners ensures they receive the most advanced and effective charging solutions available, positioning us as their preferred provider.

Q. Can you shed some light on the battery charging best practices for industrial applications?

Daniel Nuttall: To the uninitiated, it may seem that “a charger is just a charger, and a battery is just a battery; why do I need to match them?” Some original equipment manufacturers (OEMs) or end users equip their machines with an open system that allows for generic chargers and replacement batteries to be fitted. While this approach appears flexible, Delta-Q’s experience shows it can lead to suboptimal charging performance and reduced battery pack lifespan, resulting in costly warranty claims.

Industrial, construction, agriculture, outdoor power equipment, and e-mobility applications all have different operating demands, charging cycles, and service expectations. For example, an electric pallet truck (industrial) is a low discharge application, used only a few times per day for short periods over short distances. In contrast, an electric scooter (e-mobility) is a high-discharge application, often used for commutes of 35 km or more.

Therefore, it’s apparent that “one size may not fit all.” One key consideration for Delta-Q is how closely a charge profile should be tied to a particular battery and application.

Delta-Q partners closely with industrial application OEMs and battery manufacturers to create charge profiles that consider performance metrics such as allowable charging time (e.g., an overnight charging period), probable user habits (e.g., incomplete charge cycles), and the typical depth of discharge in the application.

Once a charge profile is developed, our charging solutions undergo extensive testing, including repeated cell deep discharge and low-temperature recovery, multiple charge cycles across the entire operating temperature range, overcharge control, cell equalization effectiveness testing, and efficiency testing such as those from the California Energy Commission (CEC). All these efforts aim to optimize performance, increase battery life, and ensure end-user satisfaction.

Q. What factors should one consider when choosing a battery charger for an e-mobility application?

Daniel Nuttall: Selecting the right battery charging solution for electric mobility vehicles, whether large or small, is a crucial design consideration.

Innovations in low-power, low-voltage on-board chargers have emerged to better meet the demands of various applications and the needs of operators and fleet managers. These advancements are particularly beneficial for on-board applications, where opportunistic charging opportunities can be effectively utilized.

Key considerations for choosing a charging solution in e-mobility applications include:

• high-power density
• efficient power conversion and standby modes
• robust and reliable operation in harsh environments
• optimized charging algorithms to maximize battery life and charge rate
• global regulatory compliance
• functional safety
• smart communication and vehicle networking

Delta-Q provides reliable and durable charging solutions for both on-board and off-board applications. Our chargers are designed to withstand common breakage factors and offer flexible, rapid charging profiles for different lead-acid and lithium-ion battery brands and chemistries.

Q. Can you tell us about Delta-Q's ICL series of battery chargers? 

Daniel Nuttall: The ICL Series is Delta-Q’s lithium-specific line of battery chargers for industrial and motive applications. Designed to optimally charge lithium battery systems with any chemistry (e.g., LCO, NCA, NMC, LMO, LFP, LTO), the ICL Series is IP66-rated, and its rugged, sealed aluminum die-cast enclosure protects against vibration, shock, dirt, chemicals, and fluids. This reliable, compact, and robust charging solution is constructed for harsh industrial and automotive-like environments, with environmental and reliability testing born out of the GMW3172 standard. Up to six ICL Series chargers can be stacked to achieve up to 7.5 kW of power and charge medium to large battery packs of various chemistries and DC voltages of 58 V, 85 V, and 120 V. This charger is also compliant with North American, UNECE R10 and European touch-safe voltage regulations, which allows for easy integration into electric vehicles.

ICL Series

Q. What makes Delta-Q's ICL series suitable for automotive applications?

Daniel Nuttall: Delta-Q’s products are qualified for light industrial and off-road applications. However, we recognize the demanding environments to which our charging solutions are exposed. Coupled with the high expectations of our products, we incorporate automotive processes, design approaches, and testing methods that align our charging solutions with automotive-type applications. We collaborate closely with our customers to understand their specific needs and provide tailored charging solutions or adaptations to meet their requirements.

Q. What are the main barriers to the widespread adoption of electric vehicles (EVs)? How does Delta-Q's technology help reduce this barrier?

Daniel Nuttall: There are several barriers to the widespread adoption of electric vehicles (EVs) in light industrial and off-road applications. These include supply chain disruptions, component shortages, and issues with supplier reliability. These obstacles can slow down the production and distribution of EVs, thereby affecting their adoption rate. Additionally, navigating the complex landscape of global regulatory standards and addressing electric system integration and Electromagnetic Compatibility (EMC) challenges are also significant hurdles.

Delta-Q is well-positioned to address some of the supply chain challenges. We have volume manufacturing facilities located in Europe, Asia, and the Americas, which enhance our supply chain resilience. As part of the ZAPI GROUP of companies, we collaborate with top-tier Original Equipment Manufacturers (OEMs) and hold key supplier roles in various electric vehicle segments, which helps us maintain a reliable supply of components.

Furthermore, we partner with our customers to guide them through the many global standards and regulatory bodies that exist, ensuring their products meet all requirements. We also assist in electric system integration by working alongside our customers during their system development. This includes aiding in the integration of our product, system validation, and helping secure regulatory approvals. Our support extends beyond just the charger level; we also assist at the system level.

Delta-Q’s commitment to partnership, collaboration, and innovation is what sets us apart in the industry, and by addressing some of these, we help alleviate some of the challenges faced in the adoption of electric vehicles in light industrial and off-road applications.

Q. How does Delta-Q's charging technology contribute to reducing carbon emissions?

Daniel Nuttall: Delta-Q, as part of the ZAPI GROUP of companies, in collaboration with ZIVAN, is on a mission to support the transition to electric energy across a wide range of industries, including electric golf cars, construction equipment, lift trucks, mobile elevated work platforms, and more. Our battery charging solutions enhance the performance of electric vehicles and industrial machines, with each charger having the potential to save an average of one metric ton of carbon emissions. With over four million chargers in the field, our solutions are helping OEMs reach their global emissions reduction goals. 

Q. Delta-Q Technologies has recently announced a partnership with A&K Robotics. What are the long-term goals of this partnership for sustainable urban mobility? 

Daniel Nuttall: Delta-Q and A&K Robotics share a vision of delivering eco-friendly technology and increasing global electrification. A&K plans to deploy its self-driving robot pods across busy airports, metropolitan areas, and highly populated transit zones over the next several years. These fully autonomous, compact pods feature 360° and 3-dimensional sensing systems designed to transform urban mobility, reduce environmental impact, and shape the future of transportation.

Delta-Q, an early supporter of autonomous and electrification solutions, will provide chargers for A&K’s autonomous product strategy and global expansion plans. Our goal is to make electrification and automation accessible to communities and markets worldwide, creating sustainable and attainable urban mobility. As the autonomous space grows, our partnership aims to meet the demand for reliable and eco-friendly urban transportation alternatives.

Q. What are the key goals Delta-Q has set for 2024? Is there an expansion in the company's product lineup?

Daniel Nuttall: This year, Delta-Q has been working with ZIVAN, another ZAPI GROUP company, in the creation of an unparalleled range of onboard (OBC) and off-board charging solutions, from 350 W to 36 kW. 

This represents the broadest range of battery chargers in the market that readily integrate with system electrification components, including a wide range of other ZAPI GROUP solutions, such as inverters and electric motors, as well as battery solutions through our battery partner network.

As part of the ZAPI GROUP, we leverage five decades of deep in-system and applications experience, global manufacturing and logistics, global regulatory compliance, and OEM support across multiple industries. This allows us to quickly adapt to the changing requirements of our customers and partners and positions us as the preferred provider of charging solutions.

About Daniel Nuttall

Daniel Nuttall has over 20 years of experience spanning numerous high-technology industries and applications, including research institutions, aerospace, automotive, and renewable energies. As Delta-Q’s Director of Hardware Engineering, Daniel employs adaptive and focused leadership while leading his technical teams in agile environments, ensuring high performance, team engagement, flexibility, and effectiveness during demanding research and new product development lifecycles. Daniel received his Bachelor of Electronic and Electrical Engineering degree from the University of Birmingham in the UK and holds a PhD in Power Electronics, which he received from the University of Manchester.