Matthew Allen – Solutions Manager CB Products EMEA LITHIUM ION IN MATERIALS HANDLING LITHIUM ION IN MATERIALS HANDLING
LITHIUM ION IN WAREHOUSE MATERIALS LITHIUM ION IN WAREHOUSE MATERIALS HANDLING (NOT COUNTERBALANCE) 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 2
WHERE IS LITHIUM ION 2017 WHERE 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 Freestanding batteries installed by suppliers and dealers being superseded by OEM installed ‘integrated’ battery from the factory to gain: Battery charge level gauge and ‘lift lock out’ functionality Controlled depower of machine in event of battery shut down Diagnostics and certification 3
SPECIFYING LI ION EQUIPMENT TO SATISFY AN SPECIFYING LI ION EQUIPMENT TO SATISFY AN APPLICATION REQUIRES ANALYSIS AND APPLICATION REQUIRES ANALYSIS AND MODELLING 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. 4
ELECTRIFICATION OF COUNTERBALANCE ELECTRIFICATION OF COUNTERBALANCE FORKLIFTS (WHAT IS SO GOOD ABOUT LPG?) FORKLIFTS (WHAT IS SO GOOD ABOUT LPG?) THE GAS BOTTLE Cheap and tough 10 year life with no loss of performance Clean – cannot spill. Can operate -20C to +40C No weekly ‘equalisation charge’ No battery room, eyebath required Exchanged or filled by operator in a few minutes without any equipment 5
COUNTERBALANCE MARKET TREND COUNTERBALANCE MARKET TREND ICE V ER ( WESTERN EUROPE/EU) ICE V ER ( WESTERN EUROPE/EU) Truck Capacity in Tonnes Typical Truck Types Used 1.0-2.0 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 Combustion Application Engine trucks (ICE) Intensity ? What prevents Electrification on Intensive Applications Larger Machines 6
PRODUCTIVITY COMPARISON AT 2.5T PRODUCTIVITY COMPARISON AT 2.5T IN HIGH INTENSITY OPERATION IN HIGH INTENSITY OPERATION LPG V ER LPG V ER Video of Intensive Productivity Course LPG Forklift (H2.5FT) v Electric (J2.5XN) Full Usable LPG Energy Energy Full Energy Energy Loads Per Consumption Consumptio Capacity Capacity Ah Capacity Hours Hour Kg/Hr n kWhr/hr Kg (80V) kWh Operation 59 5.2 18 3.5 H2.5FT 52 4.3 18 4.2 H2.5FT ECO eLo 58 11.7 700 42 3.6 J2.5XN 50 8.1 700 42 5.2 J2.5XN ECO eLo 7
ENERGY ON BOARD ELECTRIC FORKLIFTS V ENERGY ON BOARD ELECTRIC FORKLIFTS V GVW CAPACITIES UP TO 2.5T GVW CAPACITIES UP TO 2.5T 70 60 50 Energy on Board kWh 40 30 20 10 0 0 1000 2000 3000 4000 5000 6000 7000 8000 9000 Gross Vehicle Weight Kg Based on Specification Data from a variety of Manufacturers 8
ENERGY ON BOARD ELECTRIC FORKLIFTS V ENERGY ON BOARD ELECTRIC FORKLIFTS V GVW ALL CAPACITIES – THE BIG ELECTRIC GVW ALL CAPACITIES – THE BIG ELECTRIC MYTH MYTH 200 180 160 140 Energy on Board kWh 120 100 80 60 40 20 0 0 5000 10000 15000 20000 25000 30000 35000 Gross Vehicle Weight Kg As Electric Counterbalanced Lift Trucks Get Larger, they are less suited to intensive use , due to limitations of Energy Needed v Energy on Board. Currently available ER cannot match productivity of Large LPG/Diesel 9
MARKET DEVELOPMENT MARKET DEVELOPMENT COUNTERBALANCE FORKLIFTS EUROPE COUNTERBALANCE FORKLIFTS EUROPE (EMEA DATA) (EMEA DATA) 1-2T Forklifts 2-3T Forklifts 4-5T Forklifts LPG Electric Diesel 10 Data Source : WITS
SO HOW CAN WE SUCCESSFULLY ELECTRIFY SO HOW CAN WE SUCCESSFULLY ELECTRIFY LARGER FORKLIFTS IN INTENSIVE LARGER FORKLIFTS IN INTENSIVE OPERATIONS? OPERATIONS? Move materials more slowly? Or Find a better solution 11
HYSTER J HYSTER J 8.0XN 8.0XN Li Ion Battery , High density storage, repeated rapid opportunity charging capable, 0-100% state of charge within 1.5- 2 hrs High Voltage drive & lift system (350v), minimising system loses, improvement over current machines up to 40% more efficient than 80V Lead Acid. M ulti-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’ performance Positive Cost of Ownership vs. H9.0FT6 LPG within 3 yrs (including acquisition cost difference) 12
ADVANTAGES OF LI ION AT THIS SIZE ADVANTAGES OF LI ION AT THIS SIZE At higher power outputs lead acid batteries become less efficient Lead Acid Battery Peukert’s law becomes less efficient Impacts lead as it heats up acid battery efficiency in Lower efficiency intensive applications Causes Lead Acid Battery to heat up 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 13
Technical challenges – Larger Equipment: Batteries: Li-Ion • 800 l Diesel = 7760 kWh • 7760 kWh battery pack = 57 m 3 (114 m3 for lead-acid) , 97 tons . 14
TO TAKE ADVANTAGE OF THE BENEFITS OF LI ION TO TAKE ADVANTAGE OF THE BENEFITS OF LI ION YOU NEED TO KNOWING YOUR KILOWATTS! YOU NEED TO KNOWING YOUR KILOWATTS! Data collection on Virtual Sizing of power & energy Vehicle Model energy source Diversity in applications require tailored truck configurations 15 15
ONE SIZE DOES NOT FIT ALL ONE SIZE DOES NOT FIT ALL Application 1 Application 2 Application 3 Fixed break periods Fixed break periods Irregular break periods Normal power consumption Normal power consumption Normal to High power Opportunity charging consumption OPTION 1 OPTION 2 OPTION 3 Large Li-Ion battery M edium to Large Li-Ion battery Fuel Cell with Small Li-ion battery Conventional charging Opportunity charging Choice of charging system Low to M edium duty cycle M edium duty cycle Heavy duty cycle: 1 day w/o refill 16 16
THANKS FOR THE OPPORTUNITY TO ATTEND
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