Linde pallet stacker with Linde Li-ION batteries in storage use

Energy system for today's and tomorrow's intralogistics

Li-ION technology from Linde

Maximum uptime and flexibility

Increasing cost pressure, tight timelines and order peaks that are difficult to estimate: the dynamics of the logistics business are changing the requirements placed on warehouse equipment and forklifts. Above all, they must be constantly available and flexible in their use. At the same time, safety and cost-effectiveness count. This means that energy systems are also put to the test.

At present, it is not only in the automotive world that there are signs of a change to electro mobility. The material handling equipment industry has long been a pioneer in this field. For some time now, there has been increasing demand for electric forklifts instead of IC engine-powered trucks. The challenge: to ensure the same high vehicle availability as with trucks powered by internal combustion engines. This is where lithium-ion technology comes into play. It has proven its worth in everyday use - for example in smartphones - and offers a whole series of advantages over lead-acid batteries in forklifts:

Short and quick reloading

Battery rechargeable even during short breaks, costly and time-consuming battery changes are no longer necessary.

Higher energy efficiency

Up to 30 percent more energy through higher energy density and a high overall system efficiency.

Powerful system

No loss of performance even with decreasing battery charge.

User-friendly solution

No leaking hazardous battery gases and acids. Maintenance-free and easy to clean.

Ideal for all applications

The use of lithium-ion batteries is suitable for all applications. However, their advantages are particularly useful for intensive applications such as multi-shift operation and refrigerated storage.

Due to the elimination of emissions and possible impurities in lead-acid batteries, the technology is also particularly suitable for use in sensitive work areas such as the pharmaceutical or food industry.

For companies looking for an alternative to their internal combustion forklift fleet, lithium-ion batteries are an environmentally friendly option. This eliminates the need for retrofitting combustion vehicles with particle filters, as announced or already implemented in many countries.

Advantages of Linde's Li-ION solution

Li-ION batteries from Linde for forklift trucks and warehouse equipment improve operation and handling. They increase the availability of vehicles and make operation more economical, safer and at the same time more sustainable. Many users appreciate the practical advantages in everyday work.

Cost-effectiveness

Li-ION batteries increase the efficiency of the fleet in operation. This results from the technological advantages of this energy system, which offers numerous time and cost advantages in day-to-day logistics and for the associated infrastructure.

High system efficiency

The Li-ION solution from Linde has a particularly high system efficiency. The combination of Linde lithium-ion battery and Linde charger increases the energy yield by 30 percent compared to lead-acid batteries. This leads to lower energy costs.

Intelligent battery management

In addition, vehicle control and battery management are optimally matched to each other, for example through the CAN bus interface, which enables systems to communicate with each other. The battery system thus balances peak loads and at the same time provides sufficient energy. This protects the battery and prolongs its operating life.

Reduced maintenance and handling costs

Conventional lead-acid batteries cause a whole series of maintenance and handling costs, which are completely eliminated with lithium-ion batteries. These include, for example, the cost of a second battery, personnel costs for replenishing the batteries with water and battery replacement.

Lean charging infrastructure

In addition, there is no longer a complex charging infrastructure with a separate battery room and suction device for the gases. The charger for the lithium-ion batteries, on the other hand, can be flexibly set up at sensible waypoints, for example for short recharging in the vicinity of break areas or for saving driving time in the immediate vicinity of the application area.

Availability

To ensure smooth and efficient logistics operations, warehouse equipment and forklifts must be available at the highest possible level. This is one of the main strengths of Linde's Li-ION batteries. Unlike lead-acid batteries, the technology is highly efficient and flexible in terms of charging cycles and frequencies.

High speed charging

Linde batteries can achieve a full charge cycle within an hour. Depending on the intensity of the operation, vehicles are thus already available for several hours during the lunch break due to quick intermediate loading.

Short intermediate loading desired

With conventional batteries, it is recommended to always start only full charging cycles in order to protect the batteries. A completely different situation with lithium-ion batteries: Even extremely short interim charging of just a few minutes is not only allowed, but even desirable. Their ideal state of charge is about 20 to 80 percent of the total capacity. The overall availability of vehicles is significantly increased due to the flexibility of the charging process.

Individual protection against deep discharge

Linde's CAN bus technology allows individual settings to be made for protection against deep discharge. When approaching the minimum residual capacity, the battery management of Li-ION batteries reduces the performance of drive and lift functions. This value can be set individually for the desired balance between truck availability and battery protection.

Application-oriented capacities

Linde offers two different capacities for each type of battery. This enables companies to design the energy supply of the vehicles individually according to the operating intensity. For example, it is possible to use a forklift truck with the large battery in three-shift operation without charging during shift operation.

Safety

Linde's Li-ION technology also offers the highest level of driver and vehicle safety. Linde engineers have developed a comprehensive safety concept for the entire system consisting of battery and vehicle. During the development phase, the batteries undergo a program of special stress and crash tests.

No hazardous gases

While the hydrogen produced by lead-acid batteries can turn into dangerous oxyhydrogen gas, lithium-ion batteries eliminate this risk. In addition, the absence of the battery replacement required for lead-acid batteries means that drivers are not exposed to any risk of injury. Since the Li-ION cells are virtually maintenance-free, the operators cannot come into contact with dangerous acids.

Crash tested tray

In accidents involving forklift trucks, enormous forces are exerted by weight. To ensure that the Li-ION batteries in the vehicles are protected even in extreme situations, they have been subjected to a crash test of the maximum load. The video shows: the battery tray, thanks to 25 mm thick steel, prevents the penetration of a fork even at high speed. The mechanical design of the battery thus also meets Linde's high quality standards.

Multi-level safety system

The multi-stage safety system of Linde Li-ION batteries is applied to cell, module and battery level. In addition, battery management controls optimal battery usage by constantly monitoring and harmonizing vehicle functions, charging processes and the battery system. This prevents damage caused by overpressure, overheating, over charging or deep discharge.

In addition, not only the vehicle and battery are CE-compliant, but also the entire system consisting of vehicle, battery and charger carries the CE seal of approval for tested safety. As a rule, this is not guaranteed when purchasing the battery as a stand-alone component.

Sustainability

State-of-the-art energy systems are not only highly efficient, they also protect both people and the environment. Linde's Li-ION batteries meet all sustainability requirements. For example, their operation is completely emission-free.

In addition, the operation of forklifts and warehouse equipment with this technology is significantly more energy-efficient, which means that less energy is consumed with the same overall output.

Extended life cycle

The production of lithium-ion batteries also produces fewer pollutants than that of conventional lead-acid batteries. Another advantage of this technology is the longer life cycle of the batteries, which also helps to conserve environmental resources.

Comprehensive recycling process

At Linde, sustainability begins with the production of batteries and continues beyond the end of their life cycle. Despite their long service life, lithium-ion batteries also reach the end of their performance at some point. In this case, the batteries can be returned to all Linde network service partners. From there they are sent to a certified recycling company, with which Linde has set up a comprehensive recycling process for its lithium-ion batteries.

Here the batteries are first disassembled and their components sorted. The electronic components and cables are regularly recycled. The battery cells, on the other hand, are melted, metallurgically processed and valuable elements such as lithium, cobalt and nickel reused. With this integrated process, Linde is one of the pioneers when it comes to recycling lithium-ion batteries in intralogistics.

Seamless shift changes for fresh goods

Many bakeries already offer freshly baked bread rolls at 6 o’clock in the morning. Frequently, ingredients have to be delivered during the night to achieve that. That’s the responsibility of wholesalers like Gusto AG in Hohenpolding near Munich. Recently, Linde order pickers with lithium-ion batteries were deployed at the firm to perform the logistics work involved.

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Reliable allrounder

The NORA Centre Wolfsburg has committed itself to the fast delivery of original Volkswagen Group spare parts and other brands. Internal logistics plays an important role in meeting the demanding deadlines for customers. Crucial players are Linde electric forklifts, which prove their worth every day in the race against time - lately also equipped with Linde lithium-ion batteries.

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Innovative battery technology for forklift trucks

Electric drives are the future of mobility. This applies not only to cars, but also to forklift trucks. The key to this are new battery concepts, primarily based on lithium-ion technology. What are the advantages and disadvantages of different types of batteries? Where is the lithium-ion battery going? And how can users make the best possible use of them?

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