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Tag: batteries

GS Yuasa launches battery range in Europe

Posted on by David Priestman

GS Yuasa has launched a new range of traction batteries for the European material handling market. The launch sees the manufacturer – which describes itself as a world leader for vehicle and industrial batteries – expand upon its class-leading Japanese traction battery range with an all-new line up of European DIN and BS sizes.

The new range of individual 2V cells, full-tank solutions and accessories utilises the very latest technology and premium Japanese engineering for maximum quality and long life. Available in 24, 48 and 80V solutions, the extensive range provides coverage for all makes and models providing reliable power and hassle-free performance.

The new European-sized range is available as a fully plug-and-play solution, meaning it can be easily integrated into a wide range of applications. All batteries offer low maintenance, minimised water consumption and quick charging. They are supplied in a high durability, dip coated tray and are fully recyclable.

As an original equipment supplier, GS Yuasa says it is trusted by engineers worldwide. Its traction batteries are the preferred choice to the Asian materials handling market, and GS brand traction batteries are still widely referenced for their unrivalled quality many years after discontinuation in Europe.

James Hylton, Managing Director of GS Yuasa Battery Sales UK, said: “We’re delighted to have launched our traction range in Europe and offer our world-renowned quality and long service life to the materials handling industry.

“Our experienced engineers have developed this range using their extensive knowledge of traction technology to ensure the highest performance and reliability. We are already receiving a huge level of interest from materials handling suppliers and manufacturers who are delighted GS Yuasa have returned to the European market.”

GS Yuasa  says an optional Air-Mix system enhances electrolyte mixing, prolonging service life and reducing the risk of stratification and premature battery failure. The system brings a number of additional benefits including a 20% reduction in energy consumption during charging and reducing overall charge times by 30%. A fully integrated filling solution makes maintenance quick and easy while an optional LED indicator means electrolyte levels can be checked with just a glance.

STILL presents energy system webinar

Posted on by David Priestman

Lead-acid battery, lithium-ion technology or fuel cell? To operate economically and efficiently, you need to identify the most suitable energy system for your particular transport processes. This decision depends on many factors and therefore requires a high degree of experience. The intralogistics and energy experts of the Hamburg-based intralogistics provider STILL gave a comprehensive overview of the different energy systems during a recent “Energy” webinar and explained the advantages and disadvantages of each system in a clear and hands-on way.

Energy is becoming an increasingly important issue in intralogistics. The European Union aims to have a climate-neutral economy by 2050 at the latest – Germany even wants to achieve this goal much sooner. This means that CO2 emissions must then be avoided as far as possible or stored to the same extent as they are emitted. In order to achieve this goal, the EU Commission and the individual countries are now imposing laws and regulations to oblige everyone to make their contribution. These include increased CO2 taxes, expensive emission certificates and a complete ban on internal combustion engines, which will make electric drives mandatory for all vehicles by 2030 at the latest.

In addition, consumers are also becoming more sensitive with regard to the climate neutrality of services and products. For this reason, companies are also increasingly looking to ensure that their supply chains meet sustainability requirements. Suppliers, for instance, must provide certificates on the origin of raw materials, production conditions and the CO2 footprint. A good ecological balance sheet is thus increasingly becoming a competitive advantage.

Looking for the right energy system

One thing is true throughout Europe: Energy is precious, it is becoming ever more precious and therefore the consumption and use of energy must be managed intelligently. In intralogistics, this begins with the selection of the appropriate energy system for the drive of industrial trucks. The current choices are lead-acid batteries, lithium-ion technology, or fuel cell systems. But no matter which system is chosen, this decision will have an impact. On the infrastructure of warehouses and production sites, on the choice of transport systems, on operating costs and ultimately on the size of the investment.

“Each of these energy systems has its own special features and requires certain prerequisites in handling,” explained Dyrk Draenkow, product manager for energy systems, during the webinar. To come to a sustainable and economically efficient decision, the overall picture must be considered: transport processes, the desired handling performance, the type of vehicles and, of course, the infrastructure of the warehouse.

Suitability criteria

According to Björn Grünke, also product manager for energy systems, this leads to five criteria that can be used to identify systems that are optimally suited to the respective requirements: vehicle availability, infrastructure aspects, acquisition and operating costs, as well as sustainability. According to the expert, lead-acid batteries have a rather mediocre overall result in this analysis. While their performance in terms of vehicle availability is mediocre, they are not at all convincing in terms of infrastructure due to their high storage space requirements.

On the other hand, they come out on top when it comes to investment costs. Compared to all known energy systems, the purchase price of lead-acid batteries is very low at around 150 euros per kilowatt hour. However, this bonus is offset by the system’s only moderately efficient operating costs. And when it comes to sustainability, this energy system can only partially convince the STILL experts.

“This technology is exhausted. No further developments towards significantly shorter charging times or higher power density are to be expected,” said Draenkow and added: “However, if we disregard the limitations described, this type of battery will remain a reliable and very useful energy system for the next few years. It is especially suitable for users who have only a few vehicles and only a few working hours to deal with.”

Lithium-ion technology

Li-ion batteries can be interim charged at any time – and that within a very short time, without damaging the battery or shortening its service life. This makes it possible to use the vehicle flexibly, around the clock, without having to change the battery: lithium-ion technology thus ensures maximum availability even in multi-shift operation. And as far as charging time is concerned: in most cases, as experience has shown us, one hour of charging means up to three hours of driving.

Moreover, this energy system places very few demands on the infrastructure. When it comes to investment costs, the situation is somewhat different: Lithium-ion batteries still have a higher purchase price than lead-acid batteries. It is about two to three times as high.

“However, lithium-ion batteries have at least twice the service life with the same capacity. If you look at the general price development of lithium-ion cells since 2010, the trend is clear: They are getting cheaper and cheaper,” says Grünke. The system also stands out when it comes to sustainability. Charging and control options for increasing efficiency are constantly being developed further, while at the same time the acquisition costs for the system are being reduced.

Fuel cell systems

What is special about this energy system is that the electricity is generated within the vehicle and no longer comes out of the socket. Draenkow says: “When we talk about a fuel cell in intralogistics, we mean a so-called battery replacement module. This corresponds to a specific battery trough in terms of size, weight and shape. This means that an existing lead-acid or lithium-ion battery can be replaced one-to-one with this module. All the components necessary for a fuel cell are assembled in such a module.”

This includes the fuel cell itself, the so-called stacks. These convert the energy stored in hydrogen into electrical energy. This energy is then used to charge the integrated Li-ion battery. This is needed to supply the vehicle with continuous power. Also part of the system is a high-pressure hydrogen tank, including a fuelling nozzle and other components. It is an all-in-one system.

Since the system does not have to be charged but refuelled, there is no downtime at chargers or sockets. After only 2-3 minutes at the hydrogen pump, the vehicle is available again at full capacity. This creates maximum flexibility in terms of operating times and allows for tough demands and/or multi-shift operation without restrictions. Experience shows that a tank filling can allow up to eight hours of use, depending on the vehicle type and use.

However, the hydrogen required must be delivered by tanker truck. Or you can make yourself completely independent and produce the hydrogen yourself with your own electrolyser on the premises. This, however, requires additional electricity. If you want to be sure not to emit any CO2 in the process, you can produce the “green” energy yourself:  by wind turbine and or photovoltaics.

Of course, this involves a certain amount of effort, which is why fuel cell technology can only be rated as moderately suitable in terms of the infrastructure criterion. And with regard to investment costs: On the one hand, a “fuel cell ready” vehicle must be purchased new ex works. On the other hand, costs arise for the acquisition of the suitable fuel cell system. These are currently priced at a factor of 4-5 of a lead-acid battery. And to create the necessary infrastructure still requires high investments, so that it is currently hardly possible to profitably use fuel cells for vehicles.

However, funding programmes at the national and European level are helping to make this business case “green” in economic terms in the future. Subsidies are available both for the equipment of the vehicles and for the infrastructure. Draenkow comments: “Basically, what will apply to the future of fuel cells is the economies of scale: the more hydrogen consumers there are on the premises, the faster the costs per kilogram of hydrogen can be reduced.”

Summary

The efficiency of an energy system always depends on the particular application. Unfortunately, there is no single system for all applications. Guidance in this very confusing situation is provided by the intralogistics and energy experts of the Hamburg-based intralogistics supplier STILL – for example during the energy webinar, but they are also available anytime to offer advice and support to companies that are about to make an investment decision.

25% of electric Toyota FLTs are Lithium-ion

Posted on by David Priestman

Nearly a quarter of all Toyota electric-powered forklift trucks ordered for delivery in the UK now feature Lithium-ion battery technology.

“While lead acid remains by far the dominant battery type within the electric-powered forklift market, sales of Lithium-ion forklifts have been on a sustained upward curve for some time,” says Gary Ison, Sales Training & Product Development Manager at Toyota  Material Handling UK.

“Lead acid batteries have been a highly capable forklift power solution for years, and it is estimated that in the region of 90% of all electric forklifts in operation throughout the world are still running on these battery types. But Lithium-ion battery technology is now seen as the next evolution in forklift efficiency.”

Lithium-ion’s share of the electric forklift market is widely expected to proliferate significantly over the next five years with a report recently undertaken by India-based analyst, Research Dive, forecasting that the global Lithium-ion forklift battery market will be worth close to US$1,348.5m by 2026.

Gary Ison says: “Over the last decade or so, electric-powered forklifts have become an increasingly popular choice for businesses across all industry sectors who find themselves under growing social and legislative pressure to operate in as environmentally sensitive way as they can.

“Traditionally, electric lift trucks have relied on lead-acid battery technology but the Lithium-Ion solution has now become well established as a viable alternative. Today, in the right applications, Lithium-ion is revolutionising the way some companies operate their intralogistics processes.”

Growth in the Lithium-ion powered forklift market is being driven by a number of factors, not the least of which are the energy efficiency benefits and savings on fleet running costs that Lithium-ion offers.

But of equal significance are the advances in both battery and charger technology that have alleviated the health and safety issues that, for a while, were linked with Lithium-ion  batteries following a number of high profile fires at industrial buildings reportedly started by malfunctioning Lithium-ion batteries.

“There is no doubt that, some of the problems experienced by the early adopters of Lithium-ion battery technology made people cautious, but the science has moved on and it is easy to understand why more and more electric truck users are interested in Lithium-ion,” says Gary Ison.

He continues: “Lithium-ion batteries have the ability to be recharged in as little as one hour – which increases a truck’s overall availability. One hour’s charging will give in the region of 4 to 5 hours of operating time. Also, as these batteries allow for opportunity charging, trucks can be recharged anywhere by the operator during breaks in a shift or other periods of downtime. As a result, there is no need to swap batteries – so dedicated charging rooms and spare batteries aren’t necessary.”

Lithium-ion’s quick and easy opportunity charging functionality means that Lithium-ion battery fleets are most beneficial at sites where trucks are working at high intensity over multiple shifts or extended periods.

“Lithium-ion’s suitability as a power source for lift trucks is not driven by the number of forklifts in operation at a site but by the intensity of their schedule. A company that runs one reach truck 24 hours-a-day will benefit from switching to Lithium-ion batteries while a facility with a dozen machines that are used for light duties from 9-to-5 would commercially probably still be better served by trucks powered by lead acid batteries,” explains Gary Ison.

Infrastructural considerations

“But,” he cautions, “at any multi-shift operation with a high number of trucks working it is essential to manage and schedule operator break periods and consider the scenario where several trucks are ‘plugged in’ for recharging at the same time.

“This is because during the shorter ‘opportunity’ recharging process a Lithium-ion  battery can draw down up to four times the power from the National Grid than that which is needed to charge a traditional lead-acid battery over 8 – 12 hours.

Gary Ison continues: “If charging schedules are not properly managed and too many Lithium-ion  batteries are on charge at the same time there is risk that a building’s power supply could be overloaded.

“At Toyota we advise customers considering switching to Lithium-ion to speak to their utilities provider to flag up any potential power supply issues from the outset. But good charging discipline will deliver the consistent power levels required to allow the trucks to work around the clock – even within the most demanding environments.

“At Toyota we employ bespoke simulation software that enables us to consider all aspects of a client’s operation from the outset and model the optimum choice of battery and battery charging regime for any facility. From there we can advise on power requirements and help customers considering switching to Lithium-ion batteries to look at the bigger picture when assessing Lithium-ion batteries’ suitability for an application

“So, if you are considering switching to Lithium-ion, make sure your MHE supplier really understands your business and undertakes a thorough survey of your handling operation as well as – most importantly – the infrastructure of your site.

“With Lithium-ion offering so many benefits it is easy to forget that, for some users, the traditional lead acid battery will still represent the best option. Our pride in the Toyota brand means that we will always provide the right power solution for every electric truck application. It doesn’t matter if it’s Lithium-ion or lead acid – as long as it’s right for the customer.”

Reach trucks are Lithium-ion ready

The first three models in Toyota’s recently-launched BT Reflex family of reach trucks – the high-performance R-series, the E-series (which features Toyota’s iconic and unique tilting cab) and the flexible O-series for inside and outside use – are  all Lithium-ion ready.

The new trucks come with a choice of three intelligent energy packages to suit every customer’s application requirements: a 300 amp/hour battery for lighter duties; a 420 amp/hour battery for medium intensity work; and a 630 amp/hour solution for high intensity workhorses. All three packages are based on Toyota’s own modular Lithium-ion battery system and deliver a high degree of operational flexibility.

Lithion and UgoWork collaborate to recycle lithium batteries

Posted on by Keith McKinley

Lithion Recycling and UgoWork have signed a collaboration agreement for the recycling of lithium-ion batteries developed by UgoWork for the material handling market.

The agreement includes recycling tests of several generations of batteries produced by UgoWork at Lithion’s demonstration plant. In addition, a commercial collection, transportation and recovery process will also be developed between the two organisations to promote the sustainable and efficient recycling of lithium-ion batteries. The agreement initially covers North America.

“This collaboration with UgoWork is a great example of Quebec synergies through the lithium-ion battery industry and is fully aligned with our desire to grow this sector in Quebec,” said Benoit Couture, president of Lithion. “It is important to promote local recycling and to offer a competitive advantage to companies like UgoWork in the face of sustainable development objectives and end-of-life management requirements for lithium batteries,” he added.

“Recycling battery components that reached their end-of-life is perfectly aligned with our sustainable product development approach,” said Philippe Beauchamp, co-founder and CEO of UgoWork. “Joining forces with Lithion which has strong partnerships with companies such as Hyundai Canada, reflects our commitment to our customers and will help support our continued growth in North America.”

Hyster Li-ion forklifts overcome tough industry challenges

Posted on by David Priestman

The Hyster J2.5-3.0XNL counterbalance lift truck powered by integrated lithium-ion technology is available now to support industry applications that demand high efficiency, charging flexibility, and zero battery maintenance.

Engineered around a fully integrated and space-saving lithium-ion battery, the J2.5-3.0XNL series is at the forefront of innovation, with a design that helps free space in the operator compartment, maximising comfort, and convenience to enable high productivity. A choice of four truck models is available, for lifts up to three tonnes.

“Electric lift trucks, particularly lithium-ion forklifts, are sometimes presumed less well suited to demanding industries or outdoor applications compared to IC trucks,” says Phil Ireland, Programme Leader 20/20 Platform for Hyster Europe. “While diesel and LPG trucks are often a great fit in intensive operations, the zero-emissions Hyster J2.5-3.0XNL series can be an equally powerful addition to the fleet in many industry applications.”

Clean for Food and Beverage

In food and beverage processing, manufacture, and storage applications, lift trucks are commonly found transporting and stacking pallets within an indoor warehouse. Cleanliness is non-negotiable for preventing contamination as suppliers must meet certain standards to ensure that food safety and quality are guaranteed. Thanks to the lithium-ion battery, lift trucks from the Hyster J2.5-3.0XNL series have no fumes or acid, which could result in a spill.

The lithium-ion battery is fully integrated and does not need to be removed from the truck for charging. No lead acid batteries need to be stored on site and as the batteries are ‘maintenance free’, they also require no watering, cleaning, or equalising. Both factors again reduce potential contact with contaminants on a clean site.

Health, pharmaceutical, and paper manufacturing operations which demand high hygiene standards will also enjoy these benefits.

Food and beverage applications also need lift trucks they can depend on for toughness. As well as needing to cope with seasonal demands, materials handling equipment is often exposed to extreme temperatures when handling cold or frozen goods. Lithium-ion batteries perform well in both warm and cool environments, giving operations the flexibility to use the lift truck wherever it is needed across the entire operation.

Maximising uptime in Logistics

Logistics operations are usually high intensity, multi-shift operations that demand round the clock truck availability and maximum uptime. With fast charging times of just 1-2 hours, the Hyster J2.5-3.0XNL series lift trucks provide an effective solution for increasing operational uptime. High hour operations will often find that, despite the greater upfront investment, lithium-ion forklifts prove an economical choice over time compared to other power options.

“Opportunity charging of the lithium-ion batteries enables the J2.5-3.0XNL trucks to top up on power during break times, with no adverse effect on battery life,” says Phil. “This alternative charging strategy also saves valuable space. Where real estate is increasingly expensive, there is no need to allocate space for battery storage, or as a charging room, so more of the building footprint can be used for profitable activities.”

Plus, the design of the Hyster J2.5-3.0XNL helps free space in the operator compartment, maximising comfort, and convenience to enable the high productivity that is so essential to logistics applications.

Automotive

Bringing lithium-ion power to cars is a focus for many automotive manufacturers, and many could also benefit from using integrated lithium-ion lift trucks in their materials handling operations.

Automotive manufacturers are early adopters of technology, and keen to embrace greener power solutions. The Hyster J2.5-3.0XNL series enables automotive applications to achieve zero forklift emissions, while also benefitting from fast and flexible charging compared to lead-acid batteries. As it is possible to charge the integrated lithium-ion batteries easily during breaks, uptime is maximised across multiple shifts, meeting time-pressures and delivering high productivity.

Space saving and increased shop floor utilisation are also a key focus for automotive manufacturing and parts distribution applications. The compact design of the Hyster J2.5-3.0XNL forklifts helps deliver high performance even in these constrained areas, supporting precise retrieval and delivery of parts at the right time and in sequence.

Toughness for heavy materials handling

Operations such as DIY retailers are challenged to handle heavy palletised construction materials, where damage avoidance is key. The Hyster J2.5-J3.0XNL series provides a reliable solution, ideally suited for stacking inside a clean warehouse, loading lorries, or transporting pallets outdoors. Prefabricated metals and machine parts manufacturing can expect similar benefits.

The compact Hyster J2.5-J3.0XNL series can also prove helpful for operations loading and unloading containers with raw materials, such as in port and terminal applications. Due to the space-saving design, a lowered seat and floor plate provides easy ingress and egress from the truck, helping operators keep up with fast moving operations.

“The switch to lithium-ion powered electric trucks is a big business decision and may require changes to infrastructure and a new charging strategy,” says Phil. “However, forward-thinking companies with high intensity operations will not only be able to take advantage of productivity and cost benefits but use zero-emissions lift trucks that align with their sustainability objectives too.”

Battery charging technology aids sustainable logistics

Posted on by Keith McKinley

Battery charging technology and photovoltaics offer the perfect combination for green logistics, according to experts from Fronius.

The UK has set itself a target to bring greenhouse gas emissions down to net zero by 2050. Although this seems like a long way off, it is important that businesses start to think about their role in achieving this target and making a better, greener world for our future generations. With this end goal in mind, energy efficiency experts at Fronius are able to help their customers take the right steps towards CO­2 neutral logistics.

Companies are currently being confronted with sharply increasing electricity prices and ever stricter environmental protection requirements, coupled with changing consumer perceptions on packaging and an increase in green thinking. Seasonal peaks also present a big challenge, increasing energy consumption, and consequently driving costs and CO2­ emissions upward. In addition to efficiency and cost effectiveness, sustainability is also becoming an increasingly important subject across all sectors.

“It is apparent to us that there is a clear trend in companies wanting to reduce their CO2­ emissions and decarbonise but they are looking for feasible and practical solutions. This is what Fronius offers,” explains Beate Ruebig, Managing Director of Fronius UK. “We pride ourselves on being able to support our customers on their way to a greener logistics operation. In order to do this, our energy efficiency experts can look at the potential savings within the current operation by using Fronius solutions to reduce their ecological footprint.”

Specialising in highly efficient and intelligent conversion and control of energy for 75 years, Milton Keynes-based Fronius offer a complete package for the intralogistics industry with their energy efficient battery chargers for material handling equipment and a unique solar lease offering – both guaranteed to make savings on energy costs and reduce CO­2 emissions – making a holistic and intelligent approach to meeting the net zero targets of 2050 from a single source.

Solar powering your business

Energy costs make up a significant portion of an organisation’s overheads. Workstations, printers, machinery, forklift truck charging, lighting, air conditioning, EV charging; the list of energy hungry appliances is exhaustive, but despite the development of more efficient technologies, we continue to encounter constant energy price increases and the emergence of new electricity-reliant innovations.

The use of renewable energy, and a photovoltaic system in particular, plays a big part on the road to the 2050 targets. Distribution centres with their large, flat roofs are ideal sites for a solar PV system. The self-generated energy that they produce can power those energy hungry consumables typically found within a business, such as forklift trucks, ensuring greater independence from the grid, protecting them from energy price rises and lowering CO2­ emissions whilst taking a big step towards greater sustainability.

Many businesses worry about the initial upfront investment required to install a PV system with the ROI taking years. This is where Fronius has a solution.

With their short and unique leasing model, it is possible to achieve huge savings on your energy bill from day one, with zero upfront investment. Unlike Power Purchase Agreements, where you sell your generated electricity to offset grid electricity and the system cost, this model simply allows you to lease the equipment required to generate your own green electricity over a 15 year period, with the option of ownership thereafter.

This simple lease plan means businesses could produce their own green energy with fixed monthly payments being lower than the cost of that same electricity if purchased from the energy supplier. Complete with a production guarantee, total project management, installation and maintenance plan, this lease really is a win-win.

Energy savings inside and out

Fronius’ capabilities reach further than the roof of a warehouse but to the internal operation too. With the most progressive technology available on the market for charging traction batteries for electric forklift trucks, the Selectiva 4.0 charger range offers intelligent functions and an extremely gentle and energy-efficient process for charging lead-acid, lead-crystal, CSM and gel batteries.

The intelligent charging characteristic adapts to the state of each battery depending on its age, temperature and overall health ensuring an ultra-cool and gentle charge that will save on operating costs, electricity and reduce CO2­ at the same time.

“This technology coupled with the energy generated from your roof, can make substantial savings for a business and improve its sustainability,” explains Ruebig.

 

EnerSys offers high-performance Li-ion battery

Posted on by Keith McKinley

EnerSys, a global leader in stored energy solutions for industrial applications, has added high-performance NexSys iON batteries to its power solution portfolio.

Combining the latest lithium-ion chemistry with cost-effective modularity, NexSys iON batteries are engineered with sustainable Nickel Manganese Cobalt (NMC) large format prismatic cell chemistry that has been heavily researched and built to deliver high energy capacity in a smaller footprint.

They are designed to meet Automotive / Rigorous Functional Safety Standard ISO 26262, exceeding customary industrial compliance standards. With modular construction, the power system is precisely engineered according to operational demand, can maintain a high State of Charge (SOC) as a result of its speed of recharge capabilities and can be upsized or downsized as demands change.

“As the industry continues to evolve and operational demands continue to increase, more emphasis is being placed on the selection of lift truck and battery power solutions that are hassle-free, offer faster and more flexible charging and feature integrated power management tools for optimum safety and control,” said Harold Vanasse, Senior Director of Marketing, Motive Power Global at EnerSys.

“Our NexSys iON batteries are engineered with these characteristics in mind and provide our customers from around the world with a premium power solution that can lead to a lower Total Cost of Ownership.”

Ideal for heavy-duty applications, virtually maintenance-free NexSys iON batteries feature an integrated Battery Management System (BMS) that supports greater safety, reliability and battery life by performing auto-diagnosis, voltage limitation (charge and discharge) and communication of performance data. Additionally, fast- and opportunity-charging NexSys iON batteries with high output NexSys+ chargers provide optimised performance, productivity and enhanced fleet efficiency.

Utilising a proprietary EnSite modelling software, EnerSys can work directly with the customer to right-size a NexSys iON battery and NexSys+ charger to their vehicle fleet, helping to eliminate unwanted downtime associated with premature battery failure from improper equipment fitting or charging practices.

“Communication between the charger and battery is integral to fleet performance,” added Vanasse. “The integrated BMS featured in our NexSys iON battery is essentially the brains of the battery and can give operators even less to think about by automating the charging process.”

Varta joins Allgau in Li-ion partnership

Posted on by David Priestman

Varta and Allgau Batterie will in future bring together their expertise for the rapidly growing market for application specific configurable lithium-ion battery packs. In future, the family-owned company from Bavaria will be able to include the Easyblade and Easyblock products from Varta’s Application Specific Batteries product group in its portfolio and thus take care of all system integration issues, ranging from hardware, software and chargers to system communication and mechanical fit as well as battery design.

The Varta ASB product group are specially developed battery solutions for use in small and medium-sized vehicles such as driverless transport systems, AGVs, material handling systems or forklift trucks. The lithium-ion batteries are rugged modular and expandable and can thus be perfectly adapted to applications such as logistics or agriculture.

Thanks to its broad experience in the field of lithium-ion batteries and a strong network in various major industries, Allgau Batterie is the perfect partner for Varta’s Application Specific Batteries Easyblock and Easyblade.

Gordon Clemens, General Manager, Varta Power Pack Solutions: “The cooperation with Allgau Batterie shows that we can offer battery solutions for a wide range of applications – and without long design-in times thanks to our modular systems. For us, this marks the start of several such partnerships in Europe and the USA, because we show that Varta is the perfect partner for a quick implementation of projects where application specific configurable batteries are required.”

Manuel Diepolder, CEO of Allgau Batterie and ALLithium, is also excited about the cooperation: “With Varta, we gain a renowned partner that will help us to achieve our ambitious goals. Our companies complement each other perfectly: Varta produces excellent cells and modules which we then configure and integrate as intelligent complete systems.”

Avoiding capacity loss in forklift batteries

Posted on by David Priestman

The right battery charger plays an important role in preserving the capacity of traction batteries in the intralogistics sector. Austrian battery charger expert Fronius International GmbH looks at how its technology can be harnessed to ensure maximum forklift fleet availability and uptime.

Challenging times demand one thing above all from businesses: that they adapt quickly to new conditions and changes. The intralogistics sector is particularly feeling the effects of these expectations in the form of additional shifts, peaks in demand, and so on. For operators of electrically-powered forklift trucks, capacity and reliability are key factors because the availability of the forklift truck fleet is essential to smooth and efficient operation.

Lead-acid batteries have a standardised service life of around 1,500 charging cycles. However, particularly harsh conditions, high levels of utilisation and multi-shift operation can all have a negative impact on this. Permanent above-average usage and frequent opportunity charging in particular shorten the standardised service life of a traction battery.

Operators need to compensate for capacity losses through more frequent opportunity charging or by using back-up batteries. However, this results in longer downtime, higher running costs and reduced availability of forklift trucks. All of this has a negative impact on the total cost of ownership.

Extend battery life and reduce capital expenditure

The right battery charger makes an important contribution to ensuring maximum battery capacity for as long as possible as well as reliable operation of the fleet 24 hours a day. Thanks to the innovative Ri charging process of the Fronius Selectiva 4.0 devices, batteries receive ultra-cool and gentle charging. This extends usage and service life by as much as one year in moderate operation, without any impact on performance.

Fronius Selectiva 4.0 battery chargers are genuine all-rounders when it comes to day-to-day intralogistics activities. Conservation charging, preventing deep discharge as well as rapid and opportunity charging of lead-acid batteries are just some of the options offered by these devices. Special characteristics designed especially for charging lead-acid batteries ensure reliable, gentle and cost-effective charging to suit the condition of the battery. This enables maximum usability, even in the case of unexpected events.

For example, if a battery is not in use for an extended period of time, the Refresh characteristic ensures that its charging ability is preserved and prevents deep discharge. This guarantees that the charging level will not fall to zero and that the battery is ready for use at all times. If deep discharge nevertheless occurs, the battery can be returned to a normal state using a special characteristic. As a result, it will be usable again in no time.

If operators need extra capacity due to additional peaks in demand, for instance, this is where the Power Charging option comes in. With its help, short breaks can be used productively for rapid or opportunity charging. A lunch break of around 30 minutes can provide two additional hours of travel time.

Fronius technology thereby ensures high availability of the forklift truck fleet and also optimises operating costs. Forklift truck operators can also significantly reduce the risk of unplanned downtime in their forklift truck fleet.

Latest advances in lithium-ion forklifts

Posted on by David Priestman

Phil Ireland, Programme Leader 20/20 Platform at Hyster Europe, discusses the latest advances in lithium-ion power for Hyster lift trucks, and why common misconceptions could leave businesses missing out on the optimal solution.

In the past electric forklifts may have had a reputation for not being as ‘tough’ as their Internal Combustion Engine (ICE) counterparts. Though electric trucks thrive when matched with the right application, across the industry they can be typically seen to deliver 70% or less productivity compared to an equivalent ICE forklift. Until now.

New developments in lithium-ion

In 2020, Hyster launched the J7.0-9.0XNL series, with fully integrated lithium-ion batteries. These zero-emissions electric lift trucks with 7-9 tonnes of lift capacity offer comparable performance to an ICE truck, alongside rapid opportunity charging, due to some key advances in technology and truck design. For the first time, you can take a lithium-ion forklift, and “drive it like a diesel”.

A common objection to electric lift trucks is the run time.  It is a fact that batteries can only store so much energy, so previously operations would need to factor in the time, and infrastructure, for re-charging, making an ICE truck a simpler proposition.  However, the capability for opportunity charging with a lithium-ion battery changes that.

Operations with two or three shift operations can easily top up the charge, preventing the need for battery exchange and a separate charging room. The battery is also maintenance free with no watering or equalising, unlike a lead-acid battery. A single shift, seven-day-a-week operation using an electric forklift with a lead acid battery would, by contrast, need to equalise every six cycles for 16 hours.

What’s more, the lithium-ion battery permits high levels of regenerative braking current to be absorbed, extending run time and improving efficiency. This mode of operation is only possible on an electric lift truck and delivers the added benefit of less wear and tear on the brakes, in turn reducing maintenance costs.

The secret’s in the voltage

A key differentiator with the new Hyster J7.0-9.0XNL series is the voltage. The 350V technology makes high power charging and intensive performance possible. There is no loss in performance from frequent charging or capacity loss at heavy usage.

The higher voltage system makes it possible to charge at up to 50kW, speeding up the process. From empty, the lithium-ion battery can achieve 100% charge in less than 80 minutes. Importantly, high-power charging also allows for a quick boost – for certain applications, one minute of charging may create up to four minutes of drivetime. And the high voltage has other benefits too.

Lower voltage batteries result in a higher current for the same level of power and can overheat in intensive work cycles. Conversely, the 350V battery supports high productivity (in tonnes per hour moved) and applications with both intense peaks and continuous heavy-duty usage.

In this case, an electric truck is absolutely tough enough. The Hyster J7.0-9.0XNL series also features tough drivetrains, simple engineering, longer service intervals, and components built to last the lifetime of the truck, minimising truck maintenance needs.

There is also another important myth to address – that “electric trucks overheat all the time”. The Hyster J7.0-9.0XNL lift trucks are not only designed with a high voltage (and therefore low current) system that greatly reduces heat development, but also incorporates specially designed water-cooled motors and drive controllers to prevent this, while increasing the overall efficiency of the truck.  Battery monitoring systems are also included to keep a close eye on under and overcharging.

A green option for yellow trucks

The Hyster J7.0-9.0XNL series of electric lift trucks produce zero emissions. This is a clear benefit to those organisations aiming to improve environmental credentials.  Globally there is a move towards stricter legislation, and even total bans, on vehicles with IC engines. Organisations are therefore increasingly making the move to electric vehicles.

The ability to run and charge trucks internally without additional ventilation also provides a pollution-free alternative well suited to indoor/outdoor applications. The high controllability of electric trucks makes them an ideal option for working in confined areas, such as narrower aisle widths.

The Hyster lithium-ion forklifts are also quieter, both when working and when idling, improving operator comfort but also helping ensure that outdoor operations in urban areas comply with noise level legislation, and don’t upset the neighbours!

It depends on the application

It is important to remember that not every solution is right for every application.

Lithium-ion powered electric trucks are a more expensive initial purchase, though they have a long working life and when matched with the right application will offer productivity gains that can offset the cost.

However, low hours and less intensive operations may find the economic benefits more limited. Likewise, operations with high hours and small fleets may find opportunity charging intrusive, and large fleets may struggle to meet peak power demand capacity for charging.

Hyster has the expertise, both in-house and through our trusted dealer network, to advise on the transition from ICE to electrics, the right charging strategies, and ultimately matching the right solution to the specific needs of the application.

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