AC Power For Forklifts
- 1. AC technology - Leading the way The advantages of Jungheinrich Proprietary AC Technology in products to meet your solutions
- 2. Introduction to the AC Technology - Did you know? AC stands for Alternating Current AC motors were actually invented over 100 years ago AC motors & control systems have kept industrial applications operational for decades
- 3. Introduction to the AC Technology - Why AC? For many years DC (i.e. Direct Current) motor technology was the choice for electric trucks. Today, the advantages of AC technology have made it the cost effective power source for lift trucks, with: More energy efficiency More productivity More reliability More cost affective than their DC counterparts
- 4. Introduction to the AC Technology - Why AC? So why now in Lift trucks? Until recently it was difficult to achieve variable motor speeds with AC motors. The necessary electronics were too large & expensive for low- voltage battery applications like lift trucks. So what’s changed? Basically, the AC motor operation is the same today as it was when it was invented. But with the growing technical advances in electronics & microprocessors, AC controllers are compact, more energy efficient & cost effective. Making them advantageous & the ideal solution for use in lift trucks.
- 5. Introduction to the AC Technology - AC vs. DC DC Motor AC Motor Carbon brushes Commutator Rotor Sealed casing Sensor Bearing
- 6. Introduction to the AC Technology - AC vs. DC Shaft AC rotor core rotor Motor brushes armature commutator DC Motor AC Motor
- 7. AC Technology and our Advantages to AC The ultimate goal for any electric truck is to have minimal down time and maximum productivity whilst reducing costs . Jungheinrich AC powered trucks meet that goal: Down time & Cost : Our AC powered trucks require less frequent maintenance, they have fewer parts and run cooler. Productivity : Our AC power provides faster acceleration, efficient battery utilization & provides the operator with precision control Some users have reported up to 20% better performance in both areas
- 8. AC Technology and the Jungheinrich Benefits to AC Features and customer benefits: JH propriatary AC Controllers Higher productivity + 20% ! Higher efficiency + 30% ! Lower service costs + 20% ! Protection against dust and moisture (IP 54 Rating) Ability to provide indoor / outdoor products for your Applications With the 3 rd generation of AC controllers JH has confirmed its technology leadership! New Old
- 9. What does IP mean? The IP rating gives an “at a glance” method of recognizing the level of environmental protection that an enclosure gives the equipment/components contained within it. Ingress Protection (IP) ratings were developed by the European Committee for Electrotechnical Standardization (CENELEC) (the specification is fully described in Document IEC/EN 60529).
- 10. IP (Ingress Protection) standard table Protection against long periods of immersion under pressure. 8 Protection against the effect of immersion between 5.9“ and 39.4“ (15cm and 1m) 7 Protection against low pressure jets of water from all directions. Limited ingress permitted. 6 Totally protected againest dust. 6 Protection against low pressure jets of water from all directions. Limited ingress. 5 Protection against dust limited ingress. 5 Protection against water sprayed from all directions. Limited ingress permitted 4 Protection against solid objects up to 0.04“ (1mm) 4 Protection against direct sprays of water up to 60˚ from vertical. 3 Protection against solid objects up to 0.1“ (2.5 mm) 3 Protection against direct sprays of water up to 15˚ from the vertical. 2 Protection against solid objects up to 0.5“ (12 mm) 2 Protection against vertically falling drops of water. 1 Protection against solid objects up to 1.97“ (50 mm) 1 No protection 0 No protection 0 Protection from liquids Protection from solid objects or materials IP Ratings Table
- 11. AC Technology and our (IP) Ingress Protection Benefits Resistant to dust and moisture (IP 54) for outdoor use ” Protection from water that sprays against the equipment (casing) from all directions“ Second code number = 4: Protection levels (water) First code number = 5: Protection levels (solid parts / dust) ” Protection against harmful dust deposits. The penetration of dust is not completely prevented, but dust does not penetrate in quantities that will affect the function of the equipment“ The majority of our competitors have an IP rating of only 21 or less!
- 12. IP Rating break down by model * Motors are IP00 but due to the truck enclosure they become IP23 IP25 IP24 IP23 IP22 EKX IP25 IP24 IP23 IP22 ETX IP25 IP24 IP23 IP22 EFX IP25 IP24 IP23 IP22 EKS 314 IP23* IP23* IP23* IP23* ETR IP23* IP23* IP23* IP23* ETV IP54 IP54 IP44 IP54, IP23 EFG 4,5 IP65 IP54 IP54 IP54 EFG 2,3 IP54 n/a IP54 IP54 EFG 1 IP65 n/a IP54 IP54 ECR IP23 n/a IP54 IP54 EJC B IP54 n/a IP54 IP54 EJC IP54 n/a IP54 IP54 EJE1,2 Controllers Steering Motor Lift Motor Drive Motor Model
- 13. Jungheinrich Proprietary AC Technology Advantage True energy savings through excellent regenerative braking and reversing More power for higher productivity Resistance against dust and moisture results in lower service costs and a wider range of applications (highest IP ratings) Faster acceleration and change of travel direction (truck responds immediately to the acceleration requests) Lower service costs due to completely enclosed low maintenance-free, Jungheinrich built motors
- 14. Control is the key to AC CAN - BUS ( C ontroller A rea N etwork) Via a ring connection, all the participating elements are linked together and exchange data. Quick data transfer Data are continuously being updated and are available throughout the bus. Data are being tagged with priorities (e.g. safety issues have highest priority) and are handled accordingly. Up to 60% reduction in harness and cable connections. Steer Motor Hydraulic Pump Motor Master- Controller Drive Motor Controls Valves Display Elements RPM Sensor Temp. Sensor Steer-angle Sensor
- 15. Jungheinrich Leading the way in AC Technology 2002 2004 2005 2001 2000 1999 1998 1997 1996 Class II Order Pickers Class III Class II (NA) Class II (VNA) Class I 1 st Generation 2 nd Generation 3 rd Generation More then 125,000 AC trucks in use to date. High Performance, Lower Efficiency High Efficiency & Reliability. Much improved Efficiency. Performance & Reliability.
- 16. AC Advantages – Indoor and outdoor use Proprietary AC controllers Enclosed AC – Motors Resistant to dust and moisture (IP 54)
- 17. Benefits: use under harsher environmental conditions (moisture, dust, chemical substances) high reliability even under severe conditions reduced service and maintenance costs Customer benefits – Indoor and outdoor use AC DC AC motors: completely enclosed system Open Motors
- 18. Customer benefits - Service & maintenance AC motors are maintenance-free: No wear parts No carbon brushes No contactors Wear-free braking Customer benefits: Reduced service cost Higher reliability Reduced down-times
- 19. Customer benefits - AC savings Cost of brush change: Brushes drive motor 230 $ Brushes lift motor 160 $ Brushes steer motor 85 $ Labor 5 h 300 $ TOTAL 750 $ Cost for re-surfacing of collectors: Labor 3 h 170 $ External cost 700 $ Flat rate travel 85 $ TOTAL 955 $ -------- $ 10,640 $ 4,160 $ 1,500 Total maintenance / repair cost 5 years: -------- -------- -------- 3 x 2 motors x1 x1 $ 7,640 1 x 2 motors ----- ----- $ 1,910 ----- ----- ----- ----- Re-surfacing of collectors Drive motors Lift motor Steer motor Cost of refurbishing motors -------- -------- -------- x4 x4 x4 $ 3,000 x3 x3 x3 $ 2,250 x2 x2 x2 $ 1,500 Change brushes Drive motors (4,500-5,000 h) Lift motor (3,500-4,000 h) Steer motor (3,000-5,000 h) Cost of brushes AC Motors very demanding application demanding application normal application Maintenance Cost (10,000 hours / 5 years)
- 20. Benefits to use in your selling process high energy regeneration Acceleration as well as braking behaviour and possibilities fully possible until truck is at standstill. Controllable at any rpm rate. partially possible Regen braking very quiet acceptable noise frequency no contactors. low noise level of the motors noise of the contactors as well as of the motors at high rpm rate (carbon brushes) Noise level of the motors dynamic acceleration behaviour no torque decrease at high rpm rate higher productivity high torque output already at low rpm rate, no decrease of rpm at high torque output, progressive power output without torque dips torque drops at high rpm rate Torque reduced need for service no wear parts maintenance-free control and replacement of the carbon brushes, drive and power contactors, collector Service and maintenance safety IP 54 (EFG) IP 21 – 23 Protection degree high reliability longevity none dust, moisture Possible environmental impact unlimited outside use external cooling fins on the motor; sealed construction (EFG) airflow through the motor, open construction Cooling convenient heat balance at the cover of the motor (outside) at the collector in the “centre” of the motor; Temperature increase no contactors no „click“ noises on direction change smooth direction change electronically contactors (series wound) Control of the direction of the rotor no carbon brushes no collectors electromagnetically, without physical contact via carbon brushes, mechanically Transmission of current Benefit AC Altern. Current (AC) Direct Current (DC) Feature
- 21. Our AC Advantages - Key points for High performance High performance in small dimensions modular design high efficiency no open-air contactors Less service costs Cool running, low maintenance-free motors no brushes and contactors less cabling (60%) Outdoor use possible totally enclosed motors and controllers (IP 54) excellent gradient performance
- 22. Customer Benefits - High Performance Systems AC technology for drive, hydraulics, and steering High efficiency for optimum use of consumed energy High efficiency of hydraulic system by motor speed control High efficiency of motors without internal losses Highly dynamic and sensitive control of movements Highly economic through energy reclamation during lowering and braking
- 23. CAN-BUS (Controller Area Network) - Electronic Control Feature Truck control Minimum of cabling and connectors Higher flexibility for options and upgrades Easier operation as driver can easily adjust parameters such as speed, acceleration etc. Advantages Customer Benefits - High Performance Control inductive guidance load control Contol panel Power control
- 24. Conclusion ... Reduced operating costs through ... reduced service costs reduced energy consumption increased productivity At the same time increased operating time by ... longer battery shift life and reduced need for maintenance.. Jungheinrich AC technology is the solution even for heavy duty applications, in dusty, dirty and humid environments as well as high throughput warehousing and outdoors at low operating costs. AC Technology – Summary