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Tag: batteries

DHL Supply Chain signs contract for sustainable battery recycling

Posted on by David Priestman

DHL Supply Chain has signed a long-term contract with Fortum Battery Recycling, a business of the Nordic energy company Fortum. The agreement covers the development and provision of customized service logistics solutions for the recycling of electric vehicle (EV) batteries. With this partnership, both companies are making an important contribution to promoting sustainable supply chains and conserving valuable resources.

Fortum Battery Recycling is the only player providing a European solution for every stage of the battery recycling value chain. The company is a pioneer in the development of processes to efficiently recover valuable raw materials such as lithium, cobalt, and nickel from used batteries with minimal waste residue, thus driving forward the circular economy in electromobility. Under the agreement, DHL Supply Chain will provide customized service logistics solutions to ensure that Fortum’s recycling processes run smoothly, safely, and efficiently.

Forward-looking service logistics solutions for battery recycling

DHL Supply Chain’s service logistics goes beyond conventional logistics services. The aim is to ensure the business success of customers by guaranteeing the functionality of products and technologies throughout their life cycle. In the field of battery recycling, this means that DHL Supply Chain is responsible for the entire spectrum of services in the logistics segment. These include the safe transportation, storage, and handling of used EV batteries, as well as timely delivery to Fortum’s recycling facilities.

“Our collaboration with Fortum underscores our commitment to providing innovative logistics solutions to meet the growing demands of e-mobility,” explains Hendrik Venter, CEO at DHL Supply Chain EMEA. “Through our expertise in service logistics and our global network, we can help Fortum expand their recycling capabilities while maintaining the highest safety and sustainability standards.”

Sustainable solutions for electromobility

For Fortum, the cooperation with DHL Supply Chain is an important step in further expanding its sustainable recycling solutions and making the market for electric vehicles even more environmentally friendly. “We are proud to be working with DHL Supply Chain to develop an efficient and sustainable logistics solution for the recycling of EV batteries,” comments Anssi Airas, Head of Business Line Battery at Fortum. “We believe that electrification of Europe is not possible without sustainable recycling of batteries taking place in Europe, for Europe. The cooperation with DHL is an essential building block for our mission to promote the circular economy and maximize resource conservation.”

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Tate & Lyle Sugars goes all-in on electric HGVs

Energy Storage to be Major Challenge for Logistics Industry in 2025

Posted on by David Priestman

In its latest report, Toyota Material Handling emphasizes that energy storage will become a critical concern as electrification gains momentum.

High-Capacity Batteries: The Future of Energy Infrastructure

The Trends in Logistics 2024 report from Toyota Material Handling stresses that as companies transition to electric vehicles and battery-powered equipment, effective energy storage will be vital. The report argues that high-capacity batteries could play a crucial role in the UK’s future energy strategy, potentially powering entire industrial sites—or even cities—during times when renewable sources aren’t available.

“There is no doubt that high-capacity batteries will become a part of the overall energy landscape,” said Gary Ison, product development manager at Toyota Material Handling. “Battery manufacturers and OEMs are racing to develop batteries capable of powering electric vehicles like forklifts for extended periods while also storing renewable energy for when the sun isn’t shining and the wind isn’t blowing.” The technology could be compared to Tesla’s Powerwall systems, but on a much grander industrial scale.

The Race to Develop New Battery Technologies

The report highlights rapid advances in battery technology, pointing out that materials such as silicone, graphene, and sodium are gaining attention. Despite this, the much-hyped solid-state batteries—widely considered the future—remain expensive and difficult to produce, delaying their widespread use. This situation echoes the electric vehicle market, where models like the Tesla Model 3 and Nissan Leaf continue to rely on traditional lithium-ion batteries despite the potential of newer technologies.

Alternative Fuels Gaining Traction

In addition to advancements in batteries, Toyota’s report also highlights the growing interest in alternative fuels. Hydrotreated vegetable oil (HVO) and hydrogen are becoming popular among operators of large fleets. Hydrogen fuel cells, for example, are already in use in high-demand environments such as Amazon warehouses, where fast refueling and emission-free operation are critical. Ison explained, “For companies with access to on-site hydrogen supplies, fuel cells can be refueled in just a few minutes and enable emission-free operations.”

Grid Capacity and Renewable Energy Availability Remain Concerns

Despite the optimism around new technologies, the report warns of ongoing concerns regarding grid capacity and the availability of renewable electricity. These issues are familiar in the UK, where rising electric vehicle adoption has sparked fears of grid overload during peak times. Similar concerns could slow the logistics sector’s transition to electric power, potentially hindering the UK’s net-zero targets.

“Transitioning to sustainable energy sources is one of the most significant issues facing the supply chain sector,” said Ison. “While the shift from internal combustion engines to electric vehicles is well underway, grid stability and reliable electricity generation remain challenges.”

Navigating a Changing Energy Landscape

Toyota’s Trends in Logistics 2024 offers a snapshot of how the logistics industry is navigating the complexities of decarbonization and technological innovation. As the sector strives to balance ambitious climate goals with practical challenges, the report suggests that energy storage will be at the heart of the industry’s future.

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What stops Logistics Companies Achieving Sustainability?

Battery Economy & Safety: Li-Ion vs Lead-Acid

Posted on by David Priestman

Automated internal logistics platforms, including automated guided vehicles (AGVs), autonomous mobile robots (AMRs), and cleaning machines, are powered by an internal power source. This power source could be a lead-acid or lithium-ion battery. Both offer different performance, but they also have significant differences in terms of economy and safety.

There is no single li-ion battery type. Instead, there are several different chemistry types, each of which significantly impacts key characteristics.

Lithium-ion batteries generally come in three types, divided by their chemistry: NMC (nickel manganese cobalt oxides), NCA (nickel cobalt aluminium oxides), and LFP (iron phosphate).
On the other hand, lead-acid batteries differ in electrolyte carrier and construction. The main types of lead-acid batteries are valve regulated lead-acid (VRLA), absorbent glass mat (AGM), and gel battery (GEL).

Safety Differences Between Li-Ion and Lead-Acid

Li-ion batteries are equipped with a battery management system (BMS). This protects the battery against overvoltage and overcurrent, both of which would otherwise represent a fire hazard.
What’s more, the typical li-ion battery is double protected. The BMS monitors the current in real time, but there is also a fuse or self-control protector (SCP). Both are crucial to the safety of li-ion batteries.

Lead-acid batteries do not have a BMS, meaning that they’re solely protected by the charger. While exceeding the maximum voltage isn’t as dangerous as it would be in a li-ion battery, it can still result in the destruction of the battery. A fuse protects them from short circuits, but overcurrent protection must come from the application. What’s more, lead-acid batteries can release hydrogen while charging, meaning that they should be charged in a specific area where they can be monitored. This is not the case with li-ion batteries.

Cost Differences Between Li-Ion and Lead-Acid

The life cycle of li-ion batteries is typically longer than those of lead-acid batteries. Due to their low durability, lead-acid batteries generally only last around 500 shallow cycles, and even fewer deep cycles.

On the other hand, an LFP battery can easily cope with 2,000 cycles or more. NMC batteries offer fewer cycles, but you should still expect around 1,000 cycles. Also, the BMS in a li-ion battery will be able to monitor battery health and inform the user when a change is required. So, while a li-ion battery might have a higher initial cost, the savings over the lifespan of the batteries makes li-ion the more affordable choice for many.

Li-Ion or Lead-Acid?

Choosing which battery is best for your specific application is usually simple: li-ion batteries win in almost all areas. Li-ion batteries offer exceptional levels of safety, plus they also cost less in the long term – although the initial outlay will be higher. What’s more, li-ion batteries are more convenient, as they require less charging and replacing.

To re-cap main differences between lead-acid and high quality li-ion batteries:

As shown above, in most areas switching to li-ion provides clear advantages without compromising safety, providing high quality batteries are used. To achieve ~24V in typical battery size, two lead-acid batteries must be connected in series. Let’s analyse a simple example looking at products available on the market, comparing a 12V 50Ah lead-acid battery with a Johnson Matthey Battery Systems 21.8V li-ion battery:

Johnson Matthey Battery Systems is a leading producer of lithium-ion batteries for AGVs, AMRs, and cleaning machines. The company provides a range of li-ion options, tailored to the specific needs of the customer, all built in Europe using high-quality components and guaranteed to have exceptional performance. A European manufacturer, with a comprehensive range of services, including testing and validation, all provided under one roof. In-house laboratories allow Johnson Matthey to offer customers advanced and cost-effective testing, along with battery certification.

Charge Management Controls Energy Costs

Posted on by David Priestman

The new “connect:charger” module as part of Linde Material Handling’s (MH) fleet management solution makes the charging processes of battery-powered industrial trucks transparent and reduces electricity costs while maintaining consistent, high vehicle availability through prioritization, defined charging time slots and power limits. Suitable for use across industries, the quick-to-install software and hardware solution proves its worth even with small fleets and will be launched in time for the LogiMAT trade show.

“Peak demands in energy are among the main causes of skyrocketing costs when it comes to operating electric industrial trucks,” says Stefan Roth, Product Manager Energy Systems at Linde Material Handling. Operators of forklift trucks and warehouse equipment powered by lithium-ion batteries are especially likely to experience this because part of the concept with these applications is to charge the batteries regularly during the day in order to continuously extend their runtime. However, if too many employees connect their electric vehicles to the chargers at the same time, for example during breaks or after the end of the work shift, the power demand increases rapidly. In the case of lithium-ion batteries, this is compounded by the fact that fast charging is associated with significantly higher power demand than with the lead-acid variant.

“As the number of consumers increases, so does the risk that peaks in power consumption will occur,” Roth points out. “These short-term peaks can lead to permanent cost increases if the electricity tariff is linked to compliance with certain limit values,” he adds. But even if there are no limit values involved, with larger fleets it can be difficult to decide when to charge which vehicles in order to ensure their availability or to move charging to daytimes when electricity rates are cheaper. “All these requirements can be handled quickly and easily when using our digital charge management system, connect:charger,” explains Stefan Roth.

Intelligent charging

To do this, the new Linde system links up to 50 chargers in a network with a central hardware unit, which automatically controls the power demand according to predefined rules. Additionally, a dashboard allows forklift drivers and fleet operators to retrieve all the relevant information. For example, they can see when a particular industrial truck is ready for use again or how much energy the individual chargers have consumed over the course of the day. The dashboard also allows settings to be made with just a few clicks to adapt the charging behaviour to operational requirements. “Fixed charging times or maximum power levels can be defined. It is also possible for fleet operators to give individual chargers priority over others, for example, if a vehicle’s battery charge is below 50 percent,” explains product expert Roth. The intelligent charge management algorithm coordinates the various specifications and allocates appropriate capacities to the chargers.

There are two options as regards data transmission from the chargers to the control unit: Initially available at the market launch will be the wired solution (for up to 50 chargers). However, a wireless version will also be on offer shortly. Furthermore, there are plans to integrate additional software functions ranging from dynamic charge management and a cloud-based application to the integration of the charge management solution into a holistic energy management solution. The Linde connect:charger module can also be retrofitted, provided the charging devices feature an integrated interface (from year of manufacture 2018).

Beyond Boundaries of Charging Technology

Posted on by David Priestman

“Let’s meet up” is the theme for Fronius perfect charging technology at LogiMAT 2023 (April 25 to 27th). With their autonomous, flexible, and sustainable battery chargers, the charging experts provide answers to the challenges facing the intralogistics industry. They will be presenting their reliable solutions in Stuttgart at stand A10 in hall 10.

For intralogistics processes to be cost-effective, forklift trucks and AGVs need to be available at all times. In order to also keep the costs generated as part of this process under control, Fronius Perfect Charging also develops sustainable charging solutions with added value. These efficient battery charging systems boast a high level of availability and fault tolerance while keeping costs to a minimum. At LogiMAT 2023, fleet operators, manufacturers, and other interested parties will be able to discuss solutions that are already providing Fronius customers with answers to the challenges of tomorrow today. “LogiMAT is a great opportunity to meet up in person again after a long break. We are very much looking forward to being there,” underlines Patrick Gojer, Business Unit Manager Perfect Charging.

Fronius will be using this trade fair to highlight easy-to-implement complete concepts that push the boundaries of analog systems. The goal here is always to reduce energy costs, optimize self-consumption, and therefore increase customers’ efficiency and competitiveness. “Together we are developing ideas for safe and sustainable energy supply, in order to create genuine added value for manufacturers and users,” explains Patrick Gojer. The portfolio ranges from systems for gentle and energy-efficient charging to innovative solutions with individual charging characteristics for manufacturers in autonomous environments through to the new function PV Connect, which enables forklift trucks and AGVs to be operated using solar energy.

Over 7000 employees worldwide, a current export share of 89 percent, and 1366 active patents: that’s us, that’s Fronius. Founded in 1945 as a regional one-man operation, we are now a global player – a fact that is impressively demonstrated by our 37 international subsidiaries and our network of sales partners in more than 60 countries. And yet, at our core, we are still a family-owned company from Austria, active in photovoltaics, welding, and battery charging technology. We have always developed products and solutions for a future worth living, offering our customers an all-in-one package in the process: from advance planning and consulting to ongoing monitoring and a repair service tailored to their specific needs.

Lithium-Ion Batteries Power Automation

Posted on by David Priestman

Automated internal logistic platforms, such as AGV and AMR, as well as other industrial autonomous robots, are becoming more widespread due to lithium-ion batteries, as their apparent advantages make them more attractive than the various alternatives.

Previously, most used batteries with lead-acid based chemistry, like forklifts and other industrial mobile machines. Regardless of the specific type, these lead-acid based batteries are considered to have poor lifespans, especially when used in deep discharge cycles. The rapidly growing global market for lithium-ion batteries has allowed Johnson Matthey Battery Systems to become a leader in the industry, opening up several growth opportunities. As it now stands, the company has developed a full-service manufacturing capability, allowing it to offer a cost-effective solution for all customers.

Due to the low lifespans of lead-acid based batteries, many are now instead opting for lithium-ion batteries, which have a lifespan that’s approximately 4x longer. This is partly down to energy density, which can be up to 5x higher in li-ion batteries (50-100Wh/kg in lead-acid vs up to 260 Wh/kg in NCA/NMC cells). What’s more, lead-acid based batteries can be cumbersome, unlike Li-ion batteries, meaning they’re unsuitable for many mobile robots.

Mitigating Against Safety Concerns of Li-ion Batteries

As with many new technologies, li-ion batteries have some downsides, with the biggest being the concerns over their safety. Thermal runaway is possible in the event of overheating or overcharging, which can lead to fire. But the risk from this can be minimised. Johnson Matthey Battery Systems has achieved this by utilising a Battery Management System – which can also be used to gauge information about a battery – and by ensuring a robust mechanical design.

Moreover, most high-quality batteries have secondary backup protection, such as a fuse or SCP. A robust design is also critical, protecting the battery from physical damage while also contributing towards a long lifespan. Cell holders, cell connectors, enclosures – all should be constructed to the highest possible specifications for maximum effectiveness.

Cell Chemistry to Further Enhance Safety

LFP cell chemistry is now being used in many industrial applications to enhance safety further. This is still li-ion technology but behaves less violently when subjected to any type of force. Even ruptured LFP cells only cause smoke or minor fire contained within the battery, plus their thermal runaway temperatures are higher than NMC and NCA. LFP cells also have an exceptionally high cycle life, even with 100% Depth of Discharge (DoD). Depending on the model, the figure could reach 2,000 or more cycles, around double that of NMC and up to quadruple that of NCA. Add in DoD reduction, and the total number can be several thousand more.

There is a trade-off for the extra safety and performance: the energy density is lower than NMC and NCA – currently, it is 150-200 Wh/kg vs 220-270 Wh/kg. But the energy density is steadily improving and is already acceptable for industrial applications. What’s more, it is already up to 4x higher than that of lead-acid. Thanks to this improving energy density, LFP cells are now becoming the preferred choice for many industrial batteries.

The manufacture of LFP batteries has some challenges, but these shouldn’t stop experienced manufacturers, such as Johnson Matthey Battery Systems, from manufacturing them effectively.

Johnson Matthey Battery Systems, part of the Johnson Matthey group, is a European-based manufacturer of advanced battery systems with considerable experience within the field. The company specialises in lithium-ion battery assembly processes, manufacturing a wide range of battery packs with various applications, and operates in all other areas of battery production, including design, prototyping, and assembly. It designs and manufactures advanced battery systems of 3.6V to 60V, utilising its expertise and manufacturing capabilities to produce batteries that meet all international standards and the expectations of customers from various industries.

Currently, Johnson Matthey Battery Systems is working on several new projects, as well as internal projects to develop its manufacturing capabilities. With the market for AGVs currently increasing, the company expects to further develop its footprint in this area. One area of particular interest is improving battery pack performance by increasing lifecycles. This focus on improvement has helped JMBS to become one of the world’s most trusted li-ion battery manufacturers.

Hoppecke Cuts Freight Delivery Firm Costs

Posted on by David Priestman

A leading palletised freight delivery company is enjoying important operational benefits and reduced costs after replacing its diesel materials handling fleet with electric forklifts.

Working in partnership with battery specialist Hoppecke, Freightroute is also reducing its impact on the environment, while a quieter MHE solution is fostering a more harmonious relationship with neighbouring residents and businesses.

Since a lot of Freightroute’s operations take place at night, the switch to an electric fleet has created a much quieter and cleaner working environment. Having started the changeover in 2019, by swapping some of its diesel engine machines for battery-powered counterbalance trucks, Freightroute teamed up with Hoppecke to complete the move and maximise the benefits.

Freightroute is committed to providing its customers with a first-class end-to-end solution. The decision to switch to electric forklifts was therefore made on the understanding that the benefits to the business would not impact adversely on the quality of service provided to customers.

Hoppecke analysed the set-up, then fitted a batcoms datalogger to the existing truck batteries. Using the results to gain a better understanding of Freightroute’s daily operational requirements, Hoppecke was able to increase battery capacity by 30 per cent.

Subsequently, Freightroute adopted Hoppecke’s Trak-Air 5.5-hour charging systems, which are able to dovetail with the palletised freight operation, facilitating opportunity charging during rest periods and a full charge during the morning to lunchtime period.

Gus Whyte, Hoppecke‘s Sales Director UK and Ireland, says: “Freightroute was well-aware of the advantages of switching to battery-powered trucks. Our input helped to maximise its investment in the future of the business to deliver improved efficiency and extended battery life whilst also keeping employees safe.

“We’re delighted to help Freightroute achieve significant operational improvements with a set-up that is more efficient. Operational costs have significantly reduced due to savings from lower fuel and forklift maintenance costs.”

Hoppecke provides full maintenance support to Freightroute. The customised service contract includes battery topping and cleaning as well as charger preventative maintenance. Meanwhile, the collection of charger data supports an ongoing operational analysis with a view to driving further efficiencies.

Hoppecke Industrial Batteries is the leading specialist for industrial battery systems and at the same time the largest battery manufacturer in European ownership. Hoppecke offers to its customers around the world concepts for efficient and reliable power supply for every industrial application. A leading exponent of environmental care for more than 90 years, Hoppecke offers solutions for a variety of industries including motive power, reserve power for IT/telecoms, power stations, solar energy and UPS, special power for rail and underground. Hoppecke’s UK operation is based in Newcastle-Under-Lyme in the Midlands and the parent company has customers and business partners in many countries around the world, including Europe, the USA and China.

Wireless Charging Wisdom

Posted on by David Priestman

A new wireless charging system for e-vehicles such as AGVs and AMRs follows the maxim: ‘Charge Wisely, Charge Wirelessly’

As it opens a brand new EMEA office in Helmond, the Netherlands, Delta, a global provider of power and thermal management solutions, has introduced the brand new Wireless Charging System MOOVair Series – an innovative industrial charging solution for automated electric-driven vehicles. The newly presented MOOVair 1 kW Wireless Charging System offers up to 1 kW contactless, high efficient charging for all types of 24 V / 48 V batteries, and is suitable for automated e-vehicles that require a frequent battery charge.

Alistair Coltart, Line of Business Head for Industrial Battery Charging Solutions, said: “Driven by the growing trend of automation and digitalization within industrial applications, the usage of electric driven, battery powered autonomous vehicles is heavily increasing. This trend is requiring an automated, highly efficient and reliable battery charging process, which can be 100% supported by wireless charging technology. With decades of experience in electric and electronic technology development, Delta is ready to help our customers on this. Our new product, the MOOVair Series, supports safe, smart, wireless charging in order to enable fully automated, unmanned operation for your AGVs, AMRs, and e-vehicles in factories or other application fields.”

The 1 kW Wireless Charging System features a 1,000 W output, peak efficiency of 93%, and power transmitted over a gap of up to 20 mm. It is made of two parts: a transmitter connected to the AC supply as primary charging unit and an onboard charging unit connected to the battery. The onboard charging unit is available in versions suitable for 24 V or 48 V batteries, and multiple onboard units of either variant can share one transmitter pad saving space and cost. The onboard charging unit is compact (168 x 82 x 28 mm) and lightweight (1.5 kg, onboard charging pad included), making it simple to place inside even small e-vehicles. With the charging pads protected against water and dust to IP65, and a robust design for shock and vibration, the MOOVair Series has reliable performance even in harsh industrial environments.

Technical service

Another highlighted feature of the MOOVair Series is the choice to charge either by inbuilt profiles covering a range of batteries (bespoke profiles available on request) or by CAN bus control. With no cable, no connector wear, no maintenance downtime, smart communication and remote management, the 1 kW Wireless Charging System MOOVair truly realizes smart, automatic 24/7 operation for industrial electric vehicles manufacturers, including AGV and AMR, battery manufacturers, system integrators, industrial automation planners and solution providers.

Delta has inaugurated a new facility at the Automotive Campus in Helmond, near Eindhoven, the Netherlands to support the expansion of its industrial automation, industrial power supply and automotive business development, product testing and technical service in Europe, the Middle East & Africa (EMEA). Through the implementation of Delta’s smart energy-saving solutions and innovative eco-friendly design, the new 4,055-square metre facility is expected to consume 56.84% less electricity than traditional buildings annually. The Delta Helmond office will eventually house over 150 employees and further cement Delta’s leading capabilities for e-mobility.

Ensuring the safety of damaged electric vehicles

Posted on by David Priestman

Over recent years, the electric vehicle (EV) market has grown significantly, as we drive for sustainable solutions to support our green future. However, if EVs become damaged, safe storage and monitoring by workshops and recovery vehicles is key to prevent further risk. Tommy Carnebo, risk management specialist, Dafo Vehicle Fire Protection, discusses the risks of damaged EVs and how these can be mitigated to maximise safety.

By 2030, it’s estimated that, globally, there will be over 300 million EVs on the road (up from 16.5 million at the end of 2021). This comes as governments worldwide continue to push sustainability agendas to reduce carbon emissions. Predominately powered by lithium-ion (li-ion) batteries, EVs also present a new kind of fire risk – thermal runaway:

  1. If a battery overheats, overcharges or is subject to physical damage or overvoltage, it can cause an internal malfunction.
  2. That can lead to smoke emissions, alongside rapid temperature increases throughout the battery cells.
  3. If not controlled almost instantly, this can lead to fire, toxic emissions (eg hydrogen fluoride, carbon monoxide, carbon dioxide and cyanide) and potentially large explosions.

Thermal runaway is extremely difficult to extinguish using traditional fire suppression systems once it’s initiated. And, as EV numbers on roads continue to increase, as does the risk of thermal runaway.

For mechanic workshops, recovery vehicles, commercial vehicle handlers, first and second responders, or any other business responsible for the storage and handling of electric vehicles after road collisions, the risk of thermal runaway is particularly pertinent.

Thermal runaway is also a risk for lithium iron phosphate batteries, as they burn in the same way as li-ion batteries. However, as these batteries often contain less energy than li-ion batteries, the risk is potentially lower.

The need for a new approach

As thermal runaway can develop rapidly, for example overnight when damaged EVs are stored in a closed unit, it’s essential to have an effective fire detection system in place to maximise safety and prevent further damage to the EV, any surrounding valuable assets and the environment.

Traditional fire detection systems will often only detect thermal runaway as it advances and temperatures have begun to rise. At this stage, temperature rises can be irreversible and toxic gas emissions can cause serious health risks. Instead, damaged EVs need a unique fire detection system, which will identify thermal runaway in its earliest stage, identifying changes in the carbon monoxide levels, before temperatures increase.

As EV accidents can happen on the road, meaning damaged vehicles often need to be towed for periods of time before storage, a portable detection solution is key. This also enables the system to be applied and reused for different vehicles, giving cost savings for workshops.

By using sensors to immediately detect smoke emissions from the vehicle’s high risk areas, these detection systems can alert those nearby to the risk and can also be connected to a site’s fire alarm system, alerting first responders.

This also reduces necessary EV quarantine and downtime after a vehicle collision and makes the overall work environment safer.

Optimise energy consumption in-house

Posted on by David Priestman

Fronius Perfect Charging is offering a new effective tool for intralogistics to optimise energy consumption quickly and sustainably. With the “Load Balancing” function of the Charge & Connect software solution, fleet managers can reduce power peaks when charging lead-acid batteries and thus lower their energy costs.

Energy prices are rising massively. It is therefore even more important for companies to optimise their power consumption. One cost driver is electricity peaks. They occur when many consumers draw power at the same time – for example, when several lead-acid batteries of the electric forklift fleet are charged simultaneously. This short-term heavy load on the grid can lead to an excess of the agreed power quota, resulting in expensive additional payments and higher grid provision charges. Fronius Perfect Charging has developed a solution for this: the “Load Balancing” function of the renowned Charge & Connect connectivity software offers the opportunity of harmonising peak loads when charging lead-acid traction batteries. This prevents short-term overloads and reduces energy costs. The availability of the fleet is thereby ensured.

“The load balancing runs automatically – thanks to our intelligent charging algorithm. Once the function is activated in the Charge & Connect portal, the fleet operator can set parameters such as shift model and battery availability requirements,” explains Andreas Prielinger, Global Director RnD. “What is unique about it is that there are hardly any comparable solutions on the market for lead-acid batteries.”

The software analyses the charging process and defines the optimal and most energy-efficient charging strategy – be it through stretching, staggering or a combination of both. In this way, the required number of fully charged batteries are always available without generating heavy power peaks. Significant advantages also result from the fact that the charging curve can be individually adapted to the battery requirements as well as further charging stations or rooms can be flexibly expanded.

“Load balancing is thus a simple and at the same time efficient tool for every forklift fleet operator to keep the base load of the charging infrastructure as constant as possible and to sustainably reduce electricity consumption and costs,” Prielinger sums up.

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