Across the specialist vehicle industry, installation teams still lose hours - sometimes days - assembling their vehicle’s bespoke electrical power systems on the workshop floor. Each build becomes a small engineering project of its own, with installers juggling compatibility checks, sourcing components, and ensuring compliance under time pressure.
It’s time-consuming, difficult to scale, and increasingly hard to justify.
For Versalift, a leader in vehicle-mounted access platforms, this bottleneck had exposed an opportunity to ramp up the production speed of their Unimog-mounted insulated access platforms.
Rather than accept longer build times as “part of the process”, Versalift looked for a different approach. One that shifted complexity out of the workshop and into a modular, repeatable and scalable solution.
The problem
Versalift’s installation teams were spending significant time building electrical solutions in-house. Each install meant:
- Assembling systems from scratch
- Managing component compatibility
- Holding a wide range of stock and directly dealing with the procurement and supplier availability problems that come with this.
Versalift needed a solution that would:
- Reduce installation time
- Remove variability from electrical builds
- Cut stock holding and admin
- Maintain compliance and reliability
The Solution
Merlin addressed the challenge with a modular approach: pre-built inverter boards - turning a complex electrical install operation into a straightforward plug-and-play task.
Throughout the project, in-house engineers at Merlin provided expert consultation to guarantee the solution would integrate seamlessly with the existing architecture of the Unimog vehicle and meet the power demands.
This immediately:
- Reduced install time
- Removed compatibility concerns
- Ensured consistency across every build
Just as importantly, Versalift could now order single complete system boards as required, rather than having to source, and track stock levels of, a wide range of individual components.
Each board included:
- 1 x Merlin 24V 2000W Pure Sinewave Inverter
- 1 x 12V / 24V Battery Guard (100A, solid state)
- 1x RCD Safety Socket
overview
For specialist vehicle manufacturers under pressure to deliver more, faster - modular, pre-built electrical power systems can remove one of the most persistent constraints in the build process.
By shifting electrical complexity out of the workshop, manufacturers can reduce labour input, improve consistency, and scale production without compromising compliance or reliability.
For Versalift, the impact was immediate:
“Partnering with Merlin Power has made a real difference to our Unimog builds. Their pre-built 24V Inverter Board has helped us cut down on labour input for wiring, reduce build times, and keep consistency across every unit we produce.
The quality of their products speaks for itself, and they’ve been incredibly easy to work with from day one. Merlin Power took on the design work and helped create a solution that genuinely reduces our input while improving the end result for our customers.
It’s been a really positive partnership and has made our Unimog builds even more efficient and reliable.”
— James Heminsley, Service Management Lead – Scandinavia & UK at Versalift.
If your organisation could benefit from the efficiencies provided by pre-built electrical power system boards, get in touch today:
- Email: sales@merlin-power.com
- Phone: 01202 697 979