Tag: batteries|forklift technology|materials handling

A new partnership between Q-tronic BV – a Netherlands-based powertrain system integrator – and Italy’s Flash Battery, a leading producer of custom lithium batteries with over 500 different models and more than 200MWh supplied in 54 countries around the world, has its sights set on one of the most electrification-oriented markets in the world.

The Netherlands, Belgium and Luxembourg are the focus of the alliance between the two companies. As pointed out by Flash Battery CEO Marco Righi (pictured) and Q-tronic Managing Director Marcel Doppenberg, these areas “have set on an uncompromising journey towards far-reaching sustainability and are pushing hard for electrification, something that’s taking place in every Northern European country”.

Doppenberg explains: “With the Climate Agreement and the Climate Law, the Netherlands introduced restrictive measures in every industrial sector in order to reduce CO2 emissions, going as far as to prohibit the use of carbon.

“This evolution will drive an increasing number of manufacturers to adopt zero emissions technology and the partnership with a lithium battery expert the likes of Flash Battery will definitely accelerate this process in many OEMs.

“Q-Tronic BV, a powertrain system integrator operating in different sectors with over 40 years’ electrification experience, walks customers through the choice of components, such as motors and inverters, transaxles and battery chargers; it works on projects that are very different from one another, ranging from off-road (construction) and agricultural applications all the way to electric vehicle mobility applications, which are widely used in cities, airports and industries,” continued Righi. “Some of the most important applications we are already working on come from the construction and earth-moving sectors, especially compact loaders, which are requiring increasingly more energy in less space.”

“The partnership with Flash Battery is the natural evolution of the demand from markets needing to electrify and looking for a one-stop source for their powertrain systems,” underlined Doppenberg. “This is why integrating all the functions revolving around the electrification process is necessary: consulting, design and prototyping; quality of materials; sustainability; reliability; high performance; and, last but not least, the personalised support service demanded by SMEs and large OEMs alike (including adequate remote control systems and training of the professionals managing the systems and vehicles).

“The partnership with Flash Battery is very important to us,” he continued, “because we can now combine Flash Battery’s innovative and exclusive lithium battery technology with our expertise in the field; together we’ll be able to offer a complete powertrain system made to a very high quality level, giving us the capability to create new electrical systems equipped with lithium batteries and customised solutions built around our customers’ needs.”

Righi went on to underscore that “the partnership with Q-tronic represents a remarkable value for markets that have been oriented towards electrification for some time now and, as a result, are demanding high-quality, reliable products; we can deliver with our technological know-how and that part of the job that is essential to us, the design consulting stage, when we analyse specific requirements so that the application gets exactly the energy it needs.

“Here we are sure that supported by our product R&D activities, one of our greatest strengths, we can make a substantial contribution to the creation of tremendously innovative solutions for the manufacturers who turn to Q-tronic – high-performance and reliable solutions that have earned us a place as one of the technology partners involved in developing EU supported projects.”

 

Once again, businesses that rely on materials handling equipment (MHE) must get to grips with rising energy costs. Against a backdrop of global supply issues, new legislation and spiralling energy prices, Hoppecke is offering to help UK businesses that rely on MHE to mitigate against rising costs.

As many businesses consider switching from IC engine trucks to an electric-powered fleet, as part of its free energy audit offer, Hoppecke will assess their operation and how it uses equipment to determine the key cost savings to be made using the latest battery technology.

Meanwhile, new UK government legislation, introduced on 1st April 2022, has seen all non-agricultural businesses banned from using red diesel to power their machines, also leading to bigger energy bills. This comes at a time when unprecedented global increases in the cost of white diesel, and in turn LPG gas, are set to send energy costs spiralling ever higher.

Gus Whyte, Sales Director UK and Ireland at Hoppecke, says: “Standard lead acid batteries will suit some operations, whilst others will benefit from lithium-powered systems or other battery technologies that require regular opportunity charging. However, the big issue is recharging and electricity supply costs.

“The world energy market is changing from week to week so we’ve no idea about likely increases. Therefore, irrespective of the technology you choose, it’s vital to appreciate the costs involved in recharging batteries.”

Two key considerations govern the recharging of electric MHE: the amount of power the machine draws during operation and the charger’s percentage of inefficiency. With lithium batteries and regular opportunity charging, the amount of energy returned determines the cost of this energy replacement. It’s also influenced by the kilowatt unit cost of electricity when drawn from the AC mains supply.

Accessing low-cost energy will keep costs down. This means using off-peak time electricity, usually available between 22.00 and 06.00, to your advantage. It’s important because it can cost 28-32% less than electricity consumed at peak rate.

Employing the latest technology also helps to reduce energy bills. For example, Hoppecke say its high efficiency TCHF smart charger is 23% more efficient than a standard low frequency charger, whilst adding the company’s Trak-Air system delivers a further 11% efficiency.

For added flexibility, there’s the TCHF and TCHF Trak-Air system weekly planner. This allows charges to be pre-set individually for every day of the week. No matter what time the charger is connected to the battery, it only operates within the pre-set times, enabling businesses to benefit from full use of lower cost electricity.

Whyte adds: “After the challenges of Brexit and the Covid-19 pandemic this is an especially difficult time for logistics businesses. We’re committed to helping them really understand their energy needs so they can invest in an MHE fleet that will deliver efficiencies as well as key cost savings.”

Digital networking is taking great leaps forward in intralogistics, including in the operation of electric forklift trucks. In Charge & Connect, Fronius Perfect Charging offers a software solution that networks the charging infrastructure and enables industrially secure data transfer in real time. Users benefit from greater transparency and control of the entire charging infrastructure, giving them the power to boost the efficiency of their intralogistics.

Monitoring and managing the processes involved in charging traction batteries poses a challenge for many forklift truck operators. They often lack an overview of truck availability and current power consumption, particularly in the case of large fleets. Charge & Connect is the intelligent solution from Fronius: networking Selectiva battery chargers makes it possible to log and analyse all the relevant charging data and visualise it in a clearly arranged dashboard. The result? A range of options for users to boost intralogistics performance and reduce costs.

Cross-location, central overview

Charge & Connect displays information such as the state of charge of the connected batteries, energy consumption and the battery charger status. The user benefits from a central overview across several locations and can see where charging processes can be improved. Extensive analysis functions make it possible to find and rectify operating and application errors.

Real-time status monitoring

This software solution from Fronius Perfect Charging also helps operators to reduce downtime among their forklift truck fleets. For instance, if the charging infrastructure develops an error or fault, Charge & Connect will automatically send a push notification to the contact saved in the system. A detailed description of the error including step-by-step instructions on how to rectify it mean problems can be addressed before they result in expensive downtime or lifecycle costs.

Sustainable cost optimisation

The system also collates statistics that can be opened and viewed at any time, providing added benefits. Data from the networked charging infrastructure is analysed in the system and presented in an informative way. The statistics can be used to see whether the ideal number of traction batteries is being used, whether potential savings could be made, etc. The long-term view showing battery charger performance also helps to ascertain whether and when expensive load peaks occur. This data can be used to introduce optimisation steps and reduce energy costs.

 

Fronius UK will be opening the doors to its Technology Centre in Milton Keynes to unveil the latest innovative charging technology on offer for intralogistics, as it hosts its fifth Open House on 18th and 19th May 2022.

This is a real opportunity to explore the world of Fronius and to see up close the most recent advances in charging technology. Fronius has put together a wide variety of demonstrations across its range of products, solutions and applications and a programme of talks from specially selected guest speakers and industry partners. The event promises to be informative, hands-on and packed with fun, and whether you are looking to review your intralogistics processes, wanting to save on energy costs or simply find out what’s new, this is just the event for you.

When it comes to your warehouse and logistics operations, you are reliant on the availability and reliability of your MHE for the movement of goods. Essential to this is battery life, and this is largely defined by the charging process – a process that is often overlooked – but optimising it can save companies huge sums of money. With their unique and intelligent ‘Ri’ charging process, Fronius guarantee to save you on your energy costs across your forklift fleet – by up to 30%. With energy prices at an all-time high, if there was ever a time to review the efficiency of your charging operation, it’s now.

What’s new?

Higher power categories for heavy-duty applications – Fronius has recognised the increasing demand for electric forklift trucks for challenging heavy-duty applications. The battery charging specialist is expanding its Selectiva 4.0 product family to include powerful 96V and 120V models in order to help customers switch to sustainable, electric intralogistics systems for transporting high-tonnage goods.

New solutions for Lithium-ion batteries – the role of lithium-ion technology (Li-ion) in intralogistics is becoming increasingly important, and with good reason. Lithium-ion batteries are lightweight, have a long service life, are maintenance-free, extremely energy-efficient and have an impressive charging time of just a few minutes. All major forklift truck manufacturers now offer models with a lithium-ion battery. Fronius SelectION lithium-ion chargers offer a safe, efficient and flexible charging solution. Smart engineering by the highest quality standard ensures easy operations and reduced downtime. Thanks to its intelligent Fronius CAN protocol, a seamless and fast communication between the charger and lithium-ion battery is guaranteed.

Charge and Connect – Charge & Connect allows you to go beyond the limits of conventional charging. Increase the performance and efficiency of your intralogistics operation with this cloud-based software solution that provides real-time data and numerous analysis functions on your charging infrastructure. Combining technologically advanced chargers with a digital connectivity solution, helps you reduce energy costs, increase efficiency and minimise potential risks of downtimes.

So why not take advantage of this event to come and talk to Fronius and see some of the solutions it has on offer, whilst enjoying a schedule of entertainment, a hot lunch and refreshments throughout the day?

“The Open House is an ideal opportunity for people to visit our facility and gain an insight into the most advanced solutions available on the market.” Ross Adams, National Sales Director at Fronius UK comments, “We welcome visitors to bring their operating costs on the day and our team will be able to show them the potential savings available for their forklift fleet. We offer full solutions from single battery chargers to total system solutions including multiple charging modules and complete charging rooms, all complete with system monitoring.”

The days will also incorporate the company’s other two business units: Solar Energy and Perfect Welding. With the imminent energy price hikes, take the opportunity to look at the company’s industry leading solar products and services including its hybrid solar inverter that recently won first place for efficiency in the Energy Storage Inspection 2021 and its new powerful yet robust, project inverter for high yields, the Fronius Tauro. Fronius will also be demonstrating many of its manual, automated and robotic welding systems at the absolute forefront of welding technology.

Due to the success of its previous Open Houses, the company has made the decision to spread this year’s event across two days to allow everyone the time and space to observe demonstrations safely, provide time to speak to experts and try out products where possible. Fronius UK will welcome guests from 9:30am until 3:30pm on both days.

CLICK HERE to register to attend

UgoWork, a Canadian energy solutions provider specialising in the material handling industry, will be exhibiting at MODEX 2022, from March 28 to 31 at the Georgia World Congress Centre in Atlanta, USA.

UgoWork develops and produces lithium-ion batteries for industrial trucks that help to reduce energy costs, operational bottlenecks, and reduce global carbon footprint.

During the four-day event, UgoWork will showcase its latest innovations in lithium-ion batteries for industrial truck fleets as well as presenting its ground-breaking 24/7 Energy as a Service (EaaS) pay-per-use energy management program that mitigates CAPEX and OPEX.

“Now, more than ever before, supply chains are under unprecedented pressure to elevate their efficiency and agility – without added costs that can impact stakeholders’ bottom lines. And to achieve this goal, forklift fleet operators must consider innovative approaches and technology,” said Philippe Beauchamp, UgoWork’s President and CEO.

“With unmatched ergonomics and simplicity of its charging architecture and a revolutionary EaaS program, UgoWork is a true breath of fresh air in our market. You kind of have to see it to believe it. We are delighted with our physical presence to this MODEX edition, where warm sharing with leaders of our industry is core to innovation,” he added.

 

Clark has relaunched the GEX and GTX series. The three and four-wheel electric forklifts in 48-volt technology with load capacities of 1.6 to 2 tonnes are now also available with a lithium-ion battery (Li-Ion). With the GEX and GTX series, Clark has for the first time brought counterbalance trucks with Li-Ion battery onto the market and further expanded the product portfolio in the area of Li-Ion technology.

Customers with intensive applications in particular benefit from the properties of the Li-Ion battery, such as longevity, quick and intermediate charging capability as well as freedom from maintenance. The manoeuvrable GEX and GTX electric forklifts with Li-Ion battery are in demand wherever it is important to deliver top performance reliably and cost-efficiency day after day.

Particularly in multi-shift operations in distribution or industry, where high availability is important, also in the food, beverage, chemical and pharmaceutical industries, where clean operation is essential, the Clark electric forklifts with Li-Ion battery are an indispensable component that ensures high handling performance with low operating costs.

“The Clark lithium-ion batteries are efficient energy bundles that impress with their high availability,” explains Rolf Eiten, President & CEO Clark Europe. “When developing our lithium-ion solution, it was important to us that the customer can not only benefit from all the advantages of this technology, but that in combination with an already proven Clark electric forklift series, he receives a logistics solution at the usual price-performance ratio, which also pays off for smaller and medium-sized operations.”

Two traction motors in the parallel front drive, each with 4.4kW power and 48V three-phase technology, ensure rapid acceleration of the vehicles and travel speeds of up to 16km/h. The AC motors used are designed to be wear-free and very robust. The Zapi Dual AC control system is equipped with CAN bus technology. Three driving modes are available for energy-efficient use of the truck.

Also individually programmable are the wear-free, regenerative braking with the motor brake and the automatic reduction of speed when cornering. Safe use on ramps is guaranteed by the standard ramp function, which prevents unintentional acceleration or rolling back of the truck and ensures that the operator always has the vehicle under control.

The GTX/GEX electric trucks have lift heights of up to 7075mm. The range is available with two wheelbases. The GTX16/GEX16 has a wheelbase of 1312mm. The GTX18/GEX18 and the GTX20s and GEX20s each have a wheelbase of 1420mm.

Li-Ion – high availability with low operating costs

The Clark Li-Ion solution consists of the Li-Ion battery including battery management system (BMS) and a high-frequency charger. The battery capacity is 460Ah for all models in the GTX/GEX series. This means that both the vehicles with a smaller wheelbase and those with a larger wheelbase have the same battery power.

The 48V (160A) charger only requires a power connection (CEE 16 A plug) and fully recharges the battery in as little as 2.5 hours. The charging status of the Li-Ion battery is shown on the truck display. During the charging process, the charger’s display shows the charging status. The BMS has a safety cut-out and thus ensures safe use of the battery.

The Li-Ion battery can be temporarily charged at any time and within a very short time – whenever breaks occur and without damaging the battery or shortening its life. Approximately 6-7% of the charge quantity can be achieved in 10 minutes. Decentralised charging points directly at the place of use ensure that fast and safe charging can take place at any time.

Li-Ion trucks can thus be used around the clock without the need to change batteries. This reduces the downtimes required for battery replacement. In addition, the operator does not have to keep any exchangeable batteries or infrastructure for battery replacement. He can use the expensive storage space thus gained for other purposes.

Another advantage of the Li-Ion battery is the fact that the battery scores with a constant voltage during the entire operation. Full power is always available ⎼ even when the battery is 85% discharged. In short, Clark Li-Ion batteries bundle a lot of energy in a small space. They have an extremely long service life and are optimal for intensive use. Operators can therefore not only increase their productivity by using Li-Ion batteries, but also save costs for maintenance, infrastructure and replacement batteries.

Safe and durable

Because Clark always focuses on safety, Clark Li-Ion batteries are based on lithium iron phosphate technology (LiFePO4). With LiFePO4 batteries, no oxygen is released during the chemical reaction within the cells. This means that there is no risk of spontaneous combustion or explosion of the battery. The use of the battery is therefore very safe. Trucks with LiFePO4 battery perform efficiently even at very low and high ambient temperatures.

With 2,500 guaranteed charging cycles, the service life of the Li-Ion battery is at least twice as long, and depending on the application even many times as long, as the service life of a lead-acid battery. And even after that, the battery can still be used for 10+ years for further uses. In addition, LiFePO4 batteries are more environmentally friendly than, for example, lithium nickel manganese cobalt oxides (NMC batteries), because these require problematic raw materials, such as cobalt. Moreover, NMC batteries can burn if they leave certain operating parameters.

“The investment in a Li-Ion truck is not only worthwhile for intensive applications, but also for all drivers who want to operate a maintenance-free, long-lasting and fast-charging battery with a high safety standard,” says Eiten.

In addition to high availability and high performance, the GTX/GEX series also has a lot to offer the operator: The extremely spacious operator workplace with a generous footwell and plenty of leg and headroom ensures that operators can feel comfortable at work. A choice of adjustable comfort seats with air or mechanical suspension contribute to the high level of operator comfort. The tilt of the steering column can be individually adjusted to suit the operator.

The pedals are car-compliant. The truck can be operated either by adjustable mini-levers integrated in the armrest or by ergonomically arranged hydraulic levers on the truck bonnet. A change of direction is made via the steering column, the armrest or via a double pedal. The multi-coloured, high-contrast display provides information on all important driving parameters. Storage options for documents and mobile phones round off the workplace. In addition, thanks to the nested mast profiles, the vehicle offers the operator a very good view through the mast to the forks and the load.

Manoeuvrable and effortless to operate

The power steering ensures that the operator needs only low steering forces and few steering wheel turns when manoeuvring. With a steering angle of 101°, the GEX16-20s four-wheel forklift turns on the spot almost like a three-wheel forklift. The inner front wheel runs in the opposite direction when the steering angle is high. The rear wheel is thus not pushed over the ground. Tyre wear is thus significantly lower than with other trucks. The GTX16-20s three-wheel truck has double tyres on the steering axle as standard. With a steering angle of 90°, the three-wheel trucks therefore turn on the spot.

Tailor-made for the application

The Clark three- and four-wheel electric forklifts are available with extensive additional equipment so that they can be individually adapted to a wide range of operating conditions. The optional equipment includes, among other things, different cabs, such as rain protection (steel roof), weather protection (steel roof and front windscreen), partial (steel roof, front and rear windscreen as well as PVC side panel) and full cab, mini-levers or mechanical levers, blue LED warning lights, orange safety belt, attachments as well as additional safety options.

 

Konecranes has launched Battery as a Service (BaaS), a breakthrough innovation in both technology and business model to facilitate financing and support our customers of the E-VER range of Li-Ion powered electric forklift trucks.

Through this service, Konecranes provides chargeable, upgradable and remotely monitorable Li-ion batteries to its BaaS users. This will allow the customers to purchase an E-VER electric heavy forklift without battery and to choose the best battery set up that suits their needs. The battery is subscribed to a monthly fee, based on its actual usage which can be monitored in real-time at yourKonecranes.com customer portal (the battery becomes an OPEX). This continuous monitoring guarantees the optimal performance of the battery.

The launch of Konecranes BaaS makes the purchase decision much easier and represents a better balance between the capital expenditure (CAPEX) and the operating expenditure (OPEX) which is also more comparable to the LCC distribution of a diesel engine powered lift truck.

BaaS also represents a future-proof solution to long-existing challenges such as battery degradation, battery renewal, battery upgradability and lower resale value. This service keeps the machine resale value independent from the battery degradation.

Batteries can be renewed when the rental agreement comes to an end or if needed by the renter during the hire period.

The innovation of vehicle-battery separation and battery subscription has come true. The successful launch of BaaS is another significant milestone for Konecranes Lift Trucks.

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.”