LITHIUM ION IN MATERIALS HANDLING LITHIUM ION IN MATERIALS HANDLING - - PowerPoint PPT Presentation

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

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 Freestanding batteries installed by suppliers and dealers being superseded by OEM installed ‘integrated’ battery from the factory to gain: Battery charge level gauge and ‘lift lock out’ functionality Controlled depower of machine in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

4

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

What prevents Electrification on Intensive Applications Larger Machines Application Intensity

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

• utdoors ICE

Above 4T Mainly Internal Combustion Engine trucks (ICE)

?

6

PRODUCTIVITY COMPARISON AT 2.5T IN HIGH INTENSITY OPERATION LPG V ER 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

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

7

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

Based on Specification Data from a variety of Manufacturers

10 20 30 40 50 60 70 1000 2000 3000 4000 5000 6000 7000 8000 9000

Energy on Board kWh Gross Vehicle Weight Kg

8

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

20 40 60 80 100 120 140 160 180 200 5000 10000 15000 20000 25000 30000 35000 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

MARKET DEVELOPMENT COUNTERBALANCE FORKLIFTS EUROPE (EMEA DATA) MARKET DEVELOPMENT COUNTERBALANCE FORKLIFTS EUROPE (EMEA DATA)

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

LPG Diesel 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

11

HYSTER J 8.0XN HYSTER J 8.0XN

Li Ion Battery, High density storage, repeated rapid

• pportunity 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

Lead Acid Battery becomes less efficient as it heats up Lower efficiency Causes 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 law Impacts lead acid battery efficiency in intensive applications 13

14

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

Diversity in applications require tailored truck configurations Data collection on power & energy Virtual Vehicle Model Sizing of energy source

15 15

ONE SIZE DOES NOT FIT ALL ONE SIZE DOES NOT FIT ALL

Application 3

Irregular break periods Normal to High power consumption

OPTION 1

Large Li-Ion battery Conventional charging Low to M edium duty cycle

OPTION 2

M edium to Large Li-Ion battery Opportunity charging M edium duty cycle

OPTION 3

Fuel Cell with Small Li-ion battery Choice of charging system Heavy duty cycle: 1 day w/o refill

Application 1

Fixed break periods Normal power consumption

Application 2

Fixed break periods Normal power consumption Opportunity charging

16 16

THANKS FOR THE OPPORTUNITY TO ATTEND