Let’s Take a Look at Hatz’s Innovative Approach to Generator Technology
In the ever-evolving landscape of power generation, Hatz has consistently demonstrated a commitment to innovation and efficiency. Historically, the famed German diesel maker focused on mechanical, air-cooled engines configured for generator applications, with their Silent Pack enclosures gaining significant popularity. A pivotal moment came in 2014 with the introduction of its H-Series engines, marking a new era of compact and powerful Tier 4 Final G-Drive engines. Another breakthrough occurred in 2019 with the release of E-1 technology as the first electronic controls for single-cylinder industrial diesel engines worldwide. Building on this foundation, Hatz integrated flywheel permanent magnet generator technology (fiPMG) to lead the way in hybrid power generation. Today, the company offers 17 G-Drive and fiPMG models, with plans for further expansion this year.
“We are living in truly amazing times for power generation,” says Ben Froland, product manager for power gen at Hatz. “Conventional G-Drive diesel engines have never been cleaner or more powerful and responsive. Hybrid applications are offering new levels of fuel savings, reliability, low noise levels and reduced emissions. Hatz is excited to be part of these leaps in technology and productivity, and we’re here to help our customers realize and profit from these benefits.”
Hatz is known throughout the world as a specialist for robust and durable industrial diesel engines up to 83 hp; its North American headquarters are in Waukesha, Wisconsin. These diesel engines can be found in applications ranging from trowels and water pumps to sweepers and hybrid light towers. Hatz is also very much into power generation systems. The Hatz business field of Hatz Systems has developed special power generation units for more than 30 years with a focus on power and energy supply, scalable electricity stations and even apps in the military sector. Hatz Germany designs and manufactures individual power generation solutions from 2 to 9.5 kVA, delivering 230 or 400V. The core of these generators are Hatz’s reliable and industry-proven one-cylinder engines in the 1B- and 1D-Series. The engines and generators are engineered for demanding applications ranging from commercial building sites to farms, designed for use as grid failure solutions, grid in-feed solutions, or permanent power solutions
Of late, this power market has seen some transformative changes driven by advancements in downsized engines, telematics and alternative fuel sources. One of the standout innovations from Hatz has been its flywheel-integrated permanent magnet generator technology.
“The Hatz fiPMG allows a very small displacement diesel engine to produce clean power for DC battery charging or AC power applications,” says Froland. “The engine isn’t constrained at 1,800 rpm like a conventional generator so it can fully utilize the mechanical power available in the engine. In the case of a DC battery charging hybrid, this very small and power dense engine/PMG combination can charge a set of lithium batteries over and over again on a very small amount of diesel fuel.”
Flywheel-integrated permanent magnet generators are suitable for use in hybrid systems, as backup against power failure or for permanent power supply. They can also be used as range extenders in fully electric machines. Their versatility means that almost all application scenarios for setting up electrified systems are covered. The fiPMG solutions use a permanent magnet generator integrated into a standard-fuel engine, using a modified flywheel with magnets surrounded by a stator. This feeds an electrical current into a voltage regulator to control the voltage and current output. Using this style of electrical generator allows the user to harness the full range of engine speeds to maximize efficiency and fuel consumption as well as minimize the overall footprint of the equipment. This type of generator will also allow the user to increase the power output of their equipment by allowing the standard fuel engine to charge battery packs or capacitors, rather than powering the equipment directly.
“Generally any intermittent application is a candidate for hybridization using the fiPMG,” explains Froland. “There no longer needs to be an engine idling, ready to perform work. Instead, the energy to perform that work is stored in the batteries, and it is only tapped into when needed. As the batteries drain down, the fiPMG can quickly replenish them and the cycle repeats. We are currently supplying fiPMGs for use in everything from light towers to weather buoys to cable pullers. When operating off the batteries, the equipment is silent and zero emissions and can even be operated indoors.”
Another new power generation option from Hatz is its GD 3200 Silent Pack, which was just introduced this year at ARA’s The Rental Show in New Orleans. Equipped with Hatz’s low noise, single-cylinder diesel engines and Hatz’s fiPMG tech, the GD 3200 Silent Pack offers clean power, reduced noise emissions and optimum protection. Interestingly, Hatz is marketing this new silent pack towards the recreational vehicle or RV market, but it could work on light towers, utility trucks, ground heaters and beyond.
“As a prepacked unit the GD 3200 Silent Pack offers a very compact footprint and extremely low noise levels without requiring the OEM to go through development of their own enclosure and subsequent application review,” says Froland. “All you would have to do is hook up fuel lines, a starting battery and make your electrical connections. You can directly drive AC applications such as the RV or the ground heater. For hybrid applications you’re ready to safely charge lithium batteries in either 24V or 48V configurations.”
The quiet properties of the GD 3200 are a result of a very deliberate routing of the intake airflow with sound baffling, strategic placement of sound absorbing materials inside and mitigation of the exhaust noise, Froland goes on to explain. Vibration isolation is achieved by suspending the GD 3200 from a cradle that is allowed to move independently rather than trying to rigidly mount the base of the unit to the equipment. Telematics is also available.
“The GD 3200 works well in hot or cold environments,” says Froland. “The engine ECU can read ambient temperature and adjust engine operating parameters as needed. Additionally, the ECU will also determine the altitude the engine is operating at and further adjust accordingly.”
Hatz’s innovative approach to power generation, exemplified by its flywheel-integrated permanent magnet generator technology and the GD 3200 Silent Pack, positions the OEM as a leader in the industry. The company also offers its H-Series engines with PMG concept, which provides user-friendly hybrid drive solutions integrated into machine architectures. The combination of 3H50TIC three-cylinder and permanent magnet generator offers machine manufacturers a pre-assembled plug-and-play system that combines the advantages of robust diesel engines and direct charging of large battery banks. It’s another example of Hatz’s commitment to efficiency, environmental responsibility and customer satisfaction in power generation. As alternative power and propulsion tech like batteries enter the compact equipment market, Hatz is prepared to provide equally innovative power solutions.
“Improved lithium battery technology is changing the way power is applied,” says Froland. “Rather than spinning large displacement diesel generators for long periods of time waiting for intermittent loads, batteries allow for potential energy to be stored and used only when work is being performed. In some cases, battery energy storage systems can replace traditional gas or diesel generators if the demand is relatively small. For instances where more work needs to be done over a longer period of time, a rechargeable hybrid system makes more sense. That’s where the Hatz fiPMG technology really shines.”
Keith Gribbins is publisher of Compact Equipment.
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