Tag: forklift technology|IFOY|materials handling

In the second of our deep-dives looking at each of the IFOY Award nominated finalists ahead of the winners are announced at BMW World on 30th June, we look at the Jungheinrich ERD 220i Ride-on Electric Pallet Stacker, the second of two entries in the Special Vehicle / Warehouse Truck category.

IFOY category: Special Vehicle / Warehouse Truck

Instead of installing a large, heavy battery between the operator’s platform and the mast, as it was done previously, the ERD 220i uses two compact battery modules of 130 Ah each, which are positioned inside the vehicle chassis. The omission of the bulky battery tray offers significant advantages in the vehicle design. The truck has an L2 dimension of just 1,065 millimetres, making it the most compact vehicle in its class. Compared to its predecessor model, the ERD 220i is more than 300 millimetres shorter thanks to its new lithium-ion battery concept. The no longer required battery tray also means that the vehicle can be offered in two spacious, ergonomically designed platform variants without making any sacrifices in terms of compactness. Both platforms have fixed side guards on three sides, guaranteeing safe driving and comfortable standing.

The ERD 220i fully plays its advantages in the core area of application, lorry loading and unloading in goods handling. While the radically reduced dimensions create more space and freedom of movement in the space-intensive block storage system, the solid steel side walls provide protection on three sides when the traffic gets busy in front of the loading ramp during rush hour. On its transport journeys to the adjoining warehouse, the ERD 220i scores with its spacious driver’s workplace: comfortable driving and standing position and special support thanks to the “third side” of the platform.

Description

The Jungheinrich ERD 220i stands for uncompromising quality in every dimension. Thanks to the new lithium-ion battery concept, the dimensions of the truck are ultra-compact, while at the same time the fixed platform offers high side protection on three sides and maximum space in the generous operator workplace. This triad, combined in just one vehicle, makes our double-deck stacker the most perfect in its class.

CLICK HERE to watch a video of the ERD 220i

IFOY TEST REPORT

Until recently, you had to make a choice when it came to ride-on pallet trucks: Either go for compact or go for safe or go in the ergonomic direction. With the new ERD 220i, Jungheinrich puts an end to the dilemma of compromise.

Thanks to the integration of the lithium-ion batteries, optionally one or two units with 130 Ah each, the need for a separate battery box is eliminated. This results in a space gain of 300 millimetres, which is entirely due to the very compact dimensions, optimum operator protection and improved ergonomics.

The suspension of the standing platform can be easily adjusted to the operator’s body weight via six switches. The adjustable suspension works noticeably more comfortably. The working position is comfortable and the operator feels much better protected than with a classic pallet truck with a folding platform. Comfort is also excellent, with the possibility to lean against the side wall on both sides. The handles provide a good grip and control in any position.

Another innovation of the lift truck is the smartPILOT tiller steering. The electric steering is very intuitive and has a convenient automatic centre position for straight-line travel. The height is adjustable in four positions and the fork and lift mast are also easy to operate with one hand. The new charging interface connects the truck quickly and easily to an external fast charger (up to 300A). An integrated charger (25A) is available as an option, offering flexibility at any 230V socket.

A pallet truck with double-deck function has made its debut in the IFOY test. So there is no comparison material, but the ERD 220i moves all loads that are also used in regular pallet truck tests easily and smoothly.

The IFOY test truck is an ERD 220i in the drivePLUS version, and in its most powerful mode (P3) it achieves 11.2% higher productivity than the test average in its class for single handling – the second highest value ever. Test consumption at 100 pallets is 35% below the market average. With the maximum battery capacity of 260Ah, a practical operating time of over eight hours is possible. Longer working times are possible thanks to the possibility of easy recharging. In P2 and P1 working modes, productivity remains high and consumption drops even further.

Looking through the optional, extra-reinforced grey protective grille in the mast sometimes makes it difficult to see the fork tips, which are also grey, properly. A contrasting colour may be less beautiful, but is perhaps more practical, says the test team. By the way, the ERD 220i is equipped with a transparent plastic screen as standard.

The operationCONTROL assistance system monitors the combination of load weight and lift height at a self-selectable load centre of gravity at 500, 600 or 700mm. The funktion positionCONTROL offers various options for lift height preselection. Both digital assistance systems prove useful in the double stick test. In this test, a productivity increase of 31 percent was found compared to the transport of a single pallet. Due to the much more efficient transport, the energy consumption per 100 pallets is also lower. The practical operating time in the most powerful mode (P3) is thus up to eight hours and 36 minutes.

IFOY Test Verdict:

Working with pallet trucks is no longer a compromise between safety, compactness and ergonomics. With the new ERD 220i, Jungheinrich sets new standards for a safe, optimally protected and yet super-compact electric pallet truck. The performance is first class and challenges the competition.

IFOY INNOVATION CHECK

Market relevance: Intensive handling of goods via trucks and pallets as well as internal transport operations are the strength of the ERD 220i from Jungheinrich. The pallet stacker meets the increasing demands in terms of safety and space requirements in this area with flying colours. It is therefore seen to have a very high market relevance. The clear advantages of the truck mean that existing products are being replaced or are no longer attractive for the flexible tasks required.

Customer benefit: The ERD 220i gives the user more flexibility and safety. The compactness, which is unique in this class, increases manoeuvrability while maximising safety for the operator. The side and rear protection around the stand-on platform are only found on comparable machines with a greater overall length of 20 centimetres or more. In view of the tight space conditions when loading and unloading trucks, these are decisive advantages for the customer. In addition, the employees are supported by intelligent functions, thus meeting the requirements for ergonomics.

Novelty: The combination of compactness, safety and ergonomics is without doubt new in this class. The integrated solution for Li-Ion batteries, which has already been implemented in other types of equipment, has been implemented for the first time in the ERD 220i and leads to clear advantages. Innovative functions such as an ultrasonic sensor for speed reduction and lighting when driving over trucks underline the innovative character of the device.

Functionality / type of implementation: The ERD 220i is exemplary in its implementation. The batteries, manufactured in-house by Jungheinrich, are integrated into the vehicle chassis, which has contributed to the significant reduction in overall length. However, every additional centimetre has been extracted. A modified mast with an internal fork carriage, for example, resulted in further length savings. The new design results in a very low centre of gravity, which noticeably improves stability when driving. Operation is intuitively simple and can be further simplified by small additional features such as saveable lifting heights.

Conclusion: The ERD 220i convinces all down the line and is seen as the favourite in its category.

market relevance ++
customer benefit ++
novelty +
functionality / type of implementation ++
[++ very good / + good / Ø balanced / – less / – – not available]

For an overview of all the finalists, visit www.ifoy.org

CLICK HERE to find out more about the Jungheinrich ERD220i.

 

TEST CAMP INTRALOGISTICS is breaking new ground in the event business. When the testing event, which takes place from March 21 to 23 as part of the TEST DAYS of the IFOY AWARD at Messe Dortmund, opens its doors for the third time, it is no longer just about hands-on testing of the best intralogistics innovations. A highlight of TEST CAMP INTRALOGISTICS is likely to be a panel debate entitled Intralogistics 4.0, featuring top-drawer industry experts and moderated by Logistics Business’s News Editor Peter MacLeod.

The organiser has made sustainability a principle and taken a series of measures to effectively conserve resources. The focus is on reusability and recycling, the use of regenerative energies and, above all, the fundamental renunciation of equipment that is not absolutely necessary. The aim is to launch a new, sustainable event format in logistics.

“Everyone knows that the material battles of the past no longer fit the times,” emphasises Anita Würmser, Chairwoman of the IFOY AWARD jury, adding: “We don’t want to continue building for the bin, but create awareness that things can be done differently. That’s why we are consistently moving in the direction of environmental sustainability and want to add a new, sustainable format to the event landscape.

“The focus of TEST CAMP INTRALOGISTICS is on innovation, not decoration. I am convinced that with our focus on innovation and sustainability we are preaching to the logistics industry. Both visitors and the exhibiting companies and service providers will benefit from our measures: they will improve their own environmental balance sheet and that of their companies.”

In the area of reusability and recycling, the organiser relies, among other things, on a modular reusable booth concept. Individual booth construction is not permitted and only technically necessary equipment is located on the test areas. Only reusable aluminium trusses are used for the standardised company boxes. The modular booth system and its entire equipment, including LED lighting, company branding and rental furniture, is standardised and can be used as often as desired.

Sturdy grids are used to demarcate the driving areas, and reusable Chep pallets and containers are available for test drives. The event carpet is completely granulated after use and then reused as a secondary raw material. Trusses are also used on the main area in the congress area, and the trailer stage of the IFOY AWARD was planned on a trailer from the manufacturer Fliegl.

The organisation of event logistics from a single source ensures short distances and efficient transport, minimum water consumption and maximum conservation of resources. The central control of the material logistics for the assembly of the test areas and boxes shortens the assembly in the 10,000 sq m hall, which is fully booked, to one and a half days, and the dismantling is completed in only four hours.

The catering is also centrally organised. Exhibitors and guests use the hall restaurant for catering. Individual catering in the booth and disposable crockery are prohibited.

A big plus is the accessibility of the location. The official event hotel Mercure on the exhibition grounds is within walking distance of the hall, as is the Westfalenhallen underground station. The hotel also participates in the Planet 21 sustainability programme. Furthermore, 100 percent of the energy for the TEST CAMP comes from green electricity.

The choice of the 2021 venue already paid off in terms of the IFOY organisation’s environmental goals. As early as 2006, the Westfalenhallen was certified as an environmentally friendly eco-profit company. They have also supported the sustainability code “fairpflichtet” of the German event industry since 2014.

Four exhibition halls, including Hall 3 used by the TEST CAMP, are equipped with a photovoltaic system. Eurosolar awarded the Westfallenhallen the “European Solar Award” in 2005 in the category “owner or operator of photovoltaic systems”.

In recent years, the Westfalenhallen group of companies has implemented numerous individual measures to use energy sparingly. These include: the installation of block-type thermal power stations, the installation and use of heat recovery systems, a roof renewal with thermal insulation as well as the conversion of the ventilation control in all halls to carbon dioxide sensor technology.

The TEST CAMP INTRALOGISTICS takes place as part of the IFOY TEST DAYS of the International Intralogistics and Forklift Truck of the Year (IFOY) AWARD. It enables intralogistics decision-makers to experience innovations live and test them themselves. In addition to the 14 products and solutions of the IFOY finalists, a limited number of third-party exhibitors with innovations will be admitted for the first time. The exhibitors cover the entire spectrum of material handling – from forklifts to autonomous mobile robots (AMR) and software to holistic automation projects for high-performance warehouses.

New this year is a conference programme with panel discussions on the trend topics of innovation management, Intralogistics 4.0 and VDA 5050. A new edition of the live test of the VDA 5050 communication interface as part of the VDMA AGV Mesh-Up is also in preparation.

For the key note on the opening day, the organisers are able to welcome the internationally renowned logistics researcher Prof. Dr. Dr. h.c. Michael ten Hompel (Fraunhofer IML). National and international experts have agreed to take part in the daily panel discussions:

Panel Discussion on March 21: Without bankruptcies, bad luck and breakdowns: How companies successfully introduce intralogistics innovations. Participants: André Kranke

(Dachser), Prof. Dr. Thorsten Schmidt (TU Dresden, IFOY Innovation Check), Marco Prüglmeier (Noyes Technologies) and Dr. Jana Jost (Fraunhofer IML, moderator).

Panel Discussion on March 22: Intralogistics 4.0. Participants: Steffen Bersch (SSI Schäfer/VDMA), Jos de Vuyst (stow Group/FEM), Thomas Vortkamp (DB Schenker) Wolfgang Hillinger (DS Automotion) and Peter MacLeod (Logistics Business News Editor, IFOY juror, moderator).

VDMA Panel Discussion on March 23: VDA 5050 – status quo and future of the communication interface. Participants: Dr. Wolfgang Hackenberg (SYNAOS), Mathias Behounek, (SAFELOG), Alexander Balandin (Robert Bosch), Dr. Christian Reinema (Volkswagen Commercial Vehicles), Jan Drömer (ek robotics/VDMA, moderator).