Matthew Allen Solutions Manager CB Products EMEA

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1 Matthew Allen Solutions Manager CB Products EMEA LITHIUM ION IN MATERIALS HANDLING

2 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 2

3 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 Freestanding batteries installed by suppliers and dealers being superseded by OEM installed integrated battery from the factory to gain: Battery charge level gauge and lift lock out functionality Controlled depower of machine in event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

4 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. 4

5 ELECTRIFICATION OF COUNTERBALANCE 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

6 COUNTERBALANCE MARKET TREND ICE V ER (WESTERN EUROPE/EU) Truck Capacity in Tonnes Typical Truck Types Used Small trucks Mainly electric rider T Heart of the line Increasingly Electric in Western Europe, but intensive applications and outdoors ICE Above 4T Mainly Internal Combustion Engine trucks (ICE) Application Intensity? What prevents Electrification on Intensive Applications Larger Machines 6

7 PRODUCTIVITY COMPARISON AT 2.5T IN 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 Consumptio n kwhr/hr Full Energy Capacity Kg Full Energy Capacity Ah (80V) Usable Energy Capacity kwh Hours Operation H2.5FT H2.5FT ECO elo J2.5XN J2.5XN ECO elo

8 ENERGY ON BOARD ELECTRIC FORKLIFTS V GVW CAPACITIES UP TO 2.5T Energy on Board kwh Gross Vehicle Weight Kg Based on Specification Data from a variety of Manufacturers 8

9 ENERGY ON BOARD ELECTRIC FORKLIFTS V GVW ALL CAPACITIES THE BIG ELECTRIC MYTH Energy on Board kwh 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

10 MARKET DEVELOPMENT COUNTERBALANCE FORKLIFTS EUROPE (EMEA DATA) 1-2T Forklifts 2-3T Forklifts 4-5T Forklifts LPG Diesel Electric Data Source : WITS 10

11 SO HOW CAN WE SUCCESSFULLY ELECTRIFY LARGER FORKLIFTS IN INTENSIVE OPERATIONS? Move materials more slowly? Or Find a better solution 11

12 HYSTER J8.0XN Li Ion Battery, High density storage, repeated rapid opportunity charging capable, 0-100% state of charge within hrs High 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 performance Positive Cost of Ownership vs. H9.0FT6 LPG within 3 yrs (including acquisition cost difference) 12

13 ADVANTAGES OF LI ION AT THIS SIZE At higher power outputs lead acid batteries become less efficient Lead Acid Battery becomes less efficient as it heats up Lower efficiency Causes Lead Acid Battery to heat up Peukert s law Impacts lead acid battery efficiency in intensive applications 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

14 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

15 TO TAKE ADVANTAGE OF THE BENEFITS OF LI ION YOU NEED TO KNOWING YOUR KILOWATTS! Data collection on power & energy Virtual Vehicle Model Sizing of energy source Diversity in applications require tailored truck configurations 15 15

16 ONE SIZE DOES NOT FIT ALL Application 1 Fixed break periods Normal power consumption Application 2 Fixed break periods Normal power consumption Opportunity charging Application 3 Irregular break periods Normal to High power consumption OPTION 1 Large Li-Ion battery Conventional charging Low to Medium duty cycle OPTION 2 Medium to Large Li-Ion battery Opportunity charging Medium duty cycle OPTION 3 Fuel Cell with Small Li-ion battery Choice of charging system Heavy duty cycle: 1 day w/o refill 16 16

17 THANKS FOR THE OPPORTUNITY TO ATTEND

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