LITHIUM ION IN MATERIALS HANDLING LITHIUM ION IN MATERIALS HANDLING

Matthew Allen – Solutions Manager CB Products EMEA

LITHIUM ION IN WAREHOUSE MATERIALS HANDLING (NOT COUNTERBALANCE)LITHIUM ION IN WAREHOUSE MATERIALS HANDLING (NOT COUNTERBALANCE)

Advantages

Ability to opportunity charge quickly without detriment to life can allow multi shift operation without battery exchange

Cleanliness - Solid state and gas free when charging. Maintenance free.

More compact and lighter – beneficial in some cases (not Counterbalance)

Disadvantages

Battery cost – reducing but 4-6 X Lead Acid battery cost

Infrastructure and charger cost - installation at the workstation or lunch room may not be possible and can be expensive

Special transport and storage and disposal requirements

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WHERE IS LITHIUM ION 2017WHERE IS LITHIUM ION 2017

Much interest, spurred on by journals and shows - limited sales, (less than 1% take-up), but at least doubling annually

Growing particularly in ‘clean’ industries– food etc where current technologies have limited performance.

Most likely to be justifiable in intensive applications using multiple lead acid batteries or LPG forklifts, and ‘new builds’ where chargers can be incorporated and installed from the start, or where space in battery room is needed for other uses.

Freestanding batteries installed by suppliers and dealers being superseded by OEM installed ‘integrated’ battery from the factory to gain:

Battery charge level gauge and ‘lift lock out’ functionalityControlled depower of machine in event of battery shut downDiagnostics and certification

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SPECIFYING LI ION EQUIPMENT TO SATISFY AN APPLICATION REQUIRES ANALYSIS AND MODELLING

SPECIFYING LI ION EQUIPMENT TO SATISFY AN APPLICATION REQUIRES ANALYSIS AND MODELLING

Inputs

Application data provided by the customer particularly energy used in the application, measured or estimated.

Suitability for Li Ion based on application severity and shift and break patterns

Allows optimal size of Li Ion Battery and Charger to be selected

Total cost of ownership and payback for Lithium Ion v Lead Acid batteries

Modelling capability – allows calculation of how much charging during the shift would allow an application to move to Li ion.

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ELECTRIFICATION OF COUNTERBALANCE FORKLIFTS (WHAT IS SO GOOD ABOUT LPG?)ELECTRIFICATION OF COUNTERBALANCE FORKLIFTS (WHAT IS SO GOOD ABOUT LPG?)

THE GAS BOTTLE

Cheap and tough 10 year life with no loss of performanceClean – cannot spill. Can operate -20C to +40CNo weekly ‘equalisation charge’ No battery room, eyebath requiredExchanged or filled by operator in a few minutes without any equipment

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COUNTERBALANCE MARKET TREND ICE V ER (WESTERN EUROPE/EU)COUNTERBALANCE MARKET TREND ICE V ER (WESTERN EUROPE/EU)

What prevents Electrification on Intensive ApplicationsLarger Machines

ApplicationIntensity

Truck Capacity in Tonnes Typical Truck Types Used1.0-2.0 Small trucks Mainly electric rider

2.0-3.5T Heart of the line Increasingly Electric in Western Europe, but intensive applications and outdoors ICE

Above 4T Mainly Internal CombustionEngine trucks (ICE)

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PRODUCTIVITY COMPARISON AT 2.5TIN HIGH INTENSITY OPERATION LPG V ER

PRODUCTIVITY COMPARISON AT 2.5TIN HIGH INTENSITY OPERATION LPG V ER

Video of Intensive Productivity Course LPG Forklift (H2.5FT) v Electric (J2.5XN)

Loads Per Hour

LPG Consumption

Kg/Hr

Energy Consumption kWhr/hr

Full Energy

Capacity Kg

Full Energy Capacity Ah

(80V)

Usable Energy

Capacity kWh

Hours Operation

H2.5FT 59 5.2 18 3.5

H2.5FT ECO eLo 52 4.3 18 4.2

J2.5XN 58 11.7 700 42 3.6

J2.5XN ECO eLo 50 8.1 700 42 5.2

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ENERGY ON BOARD ELECTRIC FORKLIFTS V GVW CAPACITIES UP TO 2.5TENERGY ON BOARD ELECTRIC FORKLIFTS V GVW CAPACITIES UP TO 2.5T

Based on Specification Data from a variety of Manufacturers

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ENERGY ON BOARD ELECTRIC FORKLIFTS V GVW ALL CAPACITIES – THE BIG ELECTRIC MYTH

ENERGY ON BOARD ELECTRIC FORKLIFTS V GVW ALL CAPACITIES – THE BIG ELECTRIC MYTH

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As Electric Counterbalanced Lift Trucks Get Larger, they are less suited to intensiveuse , due to limitations of Energy Needed v Energy on Board.Currently available ER cannot match productivity of Large LPG/Diesel

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MARKET DEVELOPMENT COUNTERBALANCE FORKLIFTS EUROPE (EMEA DATA)

MARKET DEVELOPMENT COUNTERBALANCE FORKLIFTS EUROPE (EMEA DATA)

1-2T Forklifts 2-3T Forklifts 4-5T Forklifts

LPGDiesel

Electric

Data Source : WITS 10

SO HOW CAN WE SUCCESSFULLY ELECTRIFY LARGER FORKLIFTS IN INTENSIVE OPERATIONS?

SO HOW CAN WE SUCCESSFULLY ELECTRIFY LARGER FORKLIFTS IN INTENSIVE OPERATIONS?

Move materials more slowly?

Or

Find a better solution

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HYSTER J8.0XNHYSTER J8.0XN

Li Ion Battery, High density storage, repeated rapid opportunity charging capable, 0-100% state of charge within 1.5- 2 hrsHigh Voltage drive & lift system (350v), minimising system loses, improvement over current machines up to 40% more efficient than 80V Lead Acid.Multi-phase permanent magnetic motors, drive & lift 15-30% more efficient than current multi phase induction motors

Intensive 3 shift capable with opportunity charging

= Near ‘ICE like’ performancePositive Cost of Ownership vs. H9.0FT6 LPG within 3 yrs (including acquisition cost difference)

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ADVANTAGES OF LI ION AT THIS SIZEADVANTAGES OF LI ION AT THIS SIZE

Lead Acid Batterybecomes less efficient

as it heats up

Lower efficiencyCauses Lead Acid Battery to heat up

At higher power outputs lead acid batteries become less efficient

Charging also generates heat – lead acid batteries need to cool before reuse.

3X lead acid batteries may be needed and exchange of batteries this size (typically 2000kg+) is difficult and time consuming

Peukert’s lawImpacts lead acid battery efficiency inintensive applications

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Technical challenges – Larger Equipment:

Batteries: Li-Ion• 800 l Diesel = 7760 kWh• 7760 kWh battery pack

=57 m3 (114 m3 for lead-acid), 97 tons.

TO TAKE ADVANTAGE OF THE BENEFITS OF LI IONYOU NEED TO KNOWING YOUR KILOWATTS!TO TAKE ADVANTAGE OF THE BENEFITS OF LI IONYOU NEED TO KNOWING YOUR KILOWATTS!

Diversity in applications require tailored truck configurations

Data collection on power & energy

Virtual Vehicle Model

Sizing ofenergy source

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ONE SIZE DOES NOT FIT ALLONE SIZE DOES NOT FIT ALL

Application 3Irregular break periodsNormal to High power consumption

OPTION 1Large Li-Ion batteryConventional chargingLow to Medium duty cycle

OPTION 2Medium to Large Li-Ion batteryOpportunity chargingMedium duty cycle

OPTION 3Fuel Cell with Small Li-ion batteryChoice of charging systemHeavy duty cycle: 1 day w/o refill

Application 1Fixed break periodsNormal power consumption

Application 2Fixed break periodsNormal power consumptionOpportunity charging

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THANKS FOR THE OPPORTUNITY TO ATTEND