Embedded Software & Automation Solutions for Off-Highway and Heavy Equipment

Industry Overview

Off-highway machines operate in harsh, demanding environments like construction sites, mines, quarries, and industrial yards where reliability, safety, and uptime are critical.

ElectRay delivers production-grade embedded software solutions and independent engineering services for off-highway and heavy equipment OEMs, enabling intelligent control, automation, connectivity, and safety across the machine lifecycle.

From ECU software for hydraulics, powertrain, and work-equipment control to automation, operator-assist features, telematics platforms, diagnostics, and OTA systems, we help OEMs build rugged, connected, and future-ready machines for continuous-duty operation.

ElectRay’s Core Capabilities

Heavy Equipment ECU Software Development

Off-highway machines work under extreme loads and conditions. ElectRay delivers ECU software that keeps hydraulics, powertrain, traction, and work equipment responsive, stable, and safe across all terrains.

What we deliver:
• Closed-loop hydraulic control & load sensing
• Pressure/flow optimization & valve tuning
• Traction control for loose and uneven terrain
• Stability logic for cranes, booms & lifting
• Engine load management & ECO modes
• Intelligent work-equipment control (auto-lift, payload, cycles)

Automation, Operator-Assist & Semi-Autonomous Features

We deliver automation and operator-assist software systems that improve safety, productivity, and situational awareness in construction and mining environments.

Our capabilities include:

  • Sensor fusion with LiDAR, radar, cameras & GNSS/RTK
  • Object detection, terrain profiling & blind-spot elimination
  • Collision avoidance & obstacle alerts
  • Auto-leveling, return-to-dig & crane anti-sway features
  • Path planning, geo-fencing & terrain-adaptive logic
  • Fleet coordination for haul trucks and mining operations

Telematics, IoT & Fleet Management

ElectRay delivers off-highway telematics software platforms and independent engineering services to convert machine data into operational intelligence.

Solutions include:

  • Engine, hydraulic & powertrain health monitoring
  • Fuel, efficiency & cycle-time analytics
  • Operator behavior & machine utilization scoring
  • Predictive maintenance with AI-based alerts
  • Remote diagnostics, OTA/FOTA updates & cloud connectivity
  • Custom fleet dashboards and OEM portals

Communication Protocols & Safety Compliance

Modern off-highway machines require reliable communication and uncompromised safety across ECUs, sensors, and attachments. ElectRay delivers robust, interoperable software architectures compliant with global safety standards.

Our expertise includes:
• J1939, ISOBUS, UDS/OBD-II, CAN, Ethernet & Modbus
• MISRA-C compliant embedded software on NXP, TI, Renesas & Infineon
• ISO 13849, ISO 15998, ISO 19014 & IEC 61508 compliance
• Hazard analysis, FMEDA, safety architecture & validation
• Rugged software for harsh vibration, thermal & EMC conditions

Why Off-Highway OEMs Choose ElectRay

  • Rugged, safety-aligned embedded software
    Designed to operate reliably in dust, vibration, shock, extreme temperatures, and water-exposed environments.
  • Proven across heavy equipment categories
    Excavators, loaders, cranes, dozers, dump trucks, pavers, mixers, sprayers, and mining haul trucks.
  • Deep system-level software engineering
    From hydraulics and powertrain control software to telematics and perception systems fully integrated under one engineering framework.
  • Production-ready software modules
    Hydraulic control algorithms, telematics stacks, diagnostics (UDS/J1939), OTA frameworks, communication libraries, and safety software foundations.

Industries & Equipment We Support

ElectRay works across the full spectrum of off-highway and heavy-duty equipment. Our engineering teams understand the unique control, automation, and durability challenges of each machine from earthmoving to mining to material handling. Below is a clear view of the platforms we support.

Construction Equipment

We help OEMs build smarter, safer, and more automated construction machines that operate reliably in rugged job-site conditions.

Equipment we support:

  • Excavators
  • Loaders (Wheel, Backhoe, Skid-Steer)
  • Dozers & Graders
  • Compactors & Rollers
  • Mixers & Cranes
BSW for Loaders and Excavators
Remote Diagnostics for Earthmovers

Mining Equipment

Mining environments demand robust, high-precision control and advanced automation. ElectRay develops software for both open-pit and underground mining machines.

Supported equipment:

  • Haul Trucks / Mining Dumpers
  • Underground Loaders (LHDs)
  • Drill Rigs & Mining Jumbos
  • Conveyor & Material Transport Systems
  • Surface Mining Machinery

Material Handling & Specialized Machinery

ElectRay supports machines requiring precise control, load management, and safety for continuous-duty operations.

Supported platforms:

  • Telehandlers, Reach Stackers & Forklifts
  • Road Construction & Paving Equipment
  • Tunneling, Quarry & Rock-Processing Machines

Ready to Build Your Next-Generation Off-Highway Machine?

ElectRay helps OEMs accelerate development of rugged, intelligent, connected, and increasingly autonomous off-highway equipment from ECU software and automation to telematics and diagnostics platforms.

FAQ

Yes. ElectRay develops perception, sensor fusion, path-planning algorithms, and real-time control software for autonomous haulage systems used in mining environments.

Absolutely. We specialize in closed-loop hydraulic control for pumps, cylinders, valves, and load-sensing systems, including PID tuning and sensor feedback.

Yes. We provide end-to-end solutions from ECU software to cloud dashboards ensuring seamless data flow and OTA update capability.

Yes. We build safety-aligned architectures meeting ISO 13849, ISO 19014, and IEC 61508 standards for critical machinery.