FireFly Automatix has developed TorqueSyncâ„¢, a breakthrough approach to managing power demands on the company’s turf harvesters. This isn’t just another alternator, it’s a servo generator system that captures, recycles, and redistributes every bit of energy to improve both performance and fuel efficiency in real-world harvesting conditions. With over 1,300 hours of field testing, TorqueSync is the first system of its kind in mobile turf harvesting equipment to achieve full 100% regeneration.Â
The challenge with previous turf harvester generator systems
All servo motors consume power when providing positive torque (or force) to the mechanical components they are operating. When the mechanical system decelerates, the servo motors must provide negative torque to the mechanical components. Â
To provide negative torque, the servo motors generate power. For example, as the stacker decelerates, the servo motor generates a surge of extra power. That power has to go somewhere.  Â
Previous turf harvester alternators generate power based solely on demand. They reduce or stop generating power. Some of this energy is used immediately or stored briefly in capacitors. With the exception of ProSlab 160 harvesters, which are fitted with a complex system of ultra-capacitors, most of this extra energy is lost as heat.Â
The result: performance limited by the system’s ability to regulate power quickly and efficiently. Â
How TorqueSync turf harvester generator works
TorqueSync replaces the old alternator with a robust servo motor directly connected to the engine. Just like the other servo motors that drive the conveyors and stacker, this motor can handle both positive and negative torque at high speed.
TorqueSync’s Two-way Flow
Generating Electricity
When the harvester needs power, TorqueSync applies a controlled braking force (negative torque) to the engine to produce electricity.
Capturing Energy
When components slow down, TorqueSync captures energy that would otherwise be wasted and returns it to the engine as forward force (positive torque).
This two-way flow turns wasted energy into useful power, conserving fuel while boosting machine performance. Â
TorqueSync is environmentally sealed, protecting against moisture and fertilizer contamination, and it uses automotive-grade components for power regulation. The system also benefits from simplified wiring and improved airflow in the engine compartment, enhancing reliability and ease of maintenance.Â
Built for the field
The benefits of TorqueSync are clear:Â
TorqueSync captures excess power from the servo motors and feeds it directly back into the engine, achieving 100% regeneration and improving fuel economy.
TorqueSync smooths out power demands to increase harvesting speed capability and productivity.
TorqueSync comes fully sealed and engineered to withstand the harshest turf harvesting conditions.
TorqueSync uses an automotive-grade controller, proven in harsh field conditions. With over 1,300 hours of operation, it delivers consistent, dependable performance.
With TorqueSync, a fully regenerative hybrid power solution, the next generation of high-performance, energy-efficient harvesting has arrived.