T H E PA N E U R O P E A N F o r k l i f t / Wa r e h o u s e E q u i p m e n t M a g a z i n e 1. Issue 2013
ISSNNr. 18682251
Juni
Counterbalanced Lifttrucks Industrial Trucks in Hazardous Environment
Page 10–15
Special Lift Trucks New HF Charging Technology for Traction Batteries Page 32–33
11. Volume
Preface
STAPLERWORLD EUROPE 012013
Things are changing constantly! The market for industrial trucks is currently changing massively in Europe – of course the big players like Kion, Jungheinrich, Nacco and Toyota are involved at any inquiry But beside the great five or six mass manufacturers a lot of smaller companies are ramping up. Let us recall, for example, the fact that now Stoecklin is a producer of explosion proof warehouse equipment (beside the fact that they are selling Hyundaiforklifts in Switzerland). Previously only Miag and Sichelschmidt and to certain extend Linde`s affiliate Proplan. Other major manufacturers want to produce according to our information’s as well as the three mentioned before explosion proof machines. Next issue I want to address is the vast array of manufacturers for all stuff which comes not “off the shelf”. You should contact Baka, HubtexGenkinger, CVItalia, Logitrans, Armanni, Icem, Italcarelli, Doosan, FAC as well as OMG or VotexBison not to forget Belet in the Czech Republic which participated first time at LogimatShow in February 2013. The per formance of these companies which rely both on kits and taylor made parts is quite ama zing.
n– e t s a L Ihre stab ß a M r unse
In general: across Europe, the conditions of certification for industrial trucks worsen – even minor alterations to carriage, attachment or cabin can lead to a loss of license – this is from the Arctic Circle to the Mediterranean. The team of the FORKLIFTWORLD observed in many cases to careless use of warehouse technology and counterbalance trucks – so utmost care must be taken – we will help European end users and dealers searching for suitable partners for the approval of refurbished and modified trucks. The CEcompliant execution of alteration work has great impact on insurance coverage and many other legal issues – it is strongly recommended to comply with the regional law very carefully. After the big shows like Bauma or IMHX specialized fairs now will follow. For instance the TOC Terminal Operator Conference in Rotterdam for those who need to move contai ners – to the latter our English/German CONTAINER WORLD will be ready for sale naturally in time. Especially in the container handling business a lot of things happening. Konecranes will be building some reach stackers end empty container handlers for Kion in Sweden. The Kion work in Wales will be closed – production quantities and cost structure are not longer suitable. With Sany a major forklift manufacturer from China now steps into the market in Europe – four reach stackers are already working on a terminal in Rotterdam – more to follow, and indeed new ones could be completed in Bedburg near Cologne in Germany, where Sany has a modern but empty production facility in which this family owned company wanted to produce concrete pumps.
Gabelzinken bis 90 t Tragkraft Standard und Sonderausführungen in allen Formen und Abmessungen Anbaugeräte Sonderkonstruktionen und Umbauten für besondere Lastaufnahmeanforderungen
Keep up with FORKLIFTWORLD, yours very truly
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Oliver Bachmann | oba@techtexverlag.com
Hotline +49 2205 901090 Lück ISAH GmbH Im Rohnweiher 16 53797 Lohmar Germany falueck@lueck-isah.de www.lueck-isah.de
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Counterbalanced Lifttrucks
STAPLERWORLD EUROPE 012013
Content I Imprint
Counter Balanced Trucks with Electro, Gas and DieselDrivetrain, Jobstories, Interviews BYD brings low cost green efficiency to European lift truck market
5
TVH strengthens product portfolio in various segments
6
Fork Protection for Special
9
Industrial trucks for use in potentially explosive areas – placing on the market in compliance with Directive 94/9/EC and EN 17551 10 Federal German Ecodesign Award
16
VNAMarket still going strong – what are the major Trends for 2013?
18
Increasedpower rated traction battery at Villeroy & Boch
20
RoRo Special Forklift Truck delivered to BLG Logistics Group 22 Warehouse Equipment
Publishing Company TechTexVerlag GmbH & Co. KG Schaeferstrasse 2 D55257 Budenheim Tel.: +49 (0) 61 3929 34 43 Fax: +49 (0) 61 3996 04 55 info@techtexverlag.com www.techtexverlag.com www.staplerworld.com CEO Dipl.Wirtsch.Ing. Oliver Bachmann Register Court: Mainz · HRBNo.: 8678 Editor-in-Chief Oliver Bachmann Tel.: +49 (0) 61 3929 34 43 Fax: +49 (0) 61 3996 04 55 Mobile: +49 (0) 1529 21 95 80 oba@staplerworld.com Editorial Staff Susanne Obigt, Ilonka Schwing (STAPLERFACTS)
Reachtrucks, OrderPickers, VNATrucks, Terminals, Scheduling Systems etc. Advertorial Mast profiles: Partnership from the very beginning
26
Pallets automatically detected and localized
28
Prevent the MachineTheft: Not as expensive as we thought!
30
Innovation push in Dornach: New exvehicles and Li ON technology are coming
31
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Special Lift Trucks
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Sideloaders, Telescoping Handlers, Compact Trucks, Tow Tractors, ContainerhandlingEquipment Pioneering cutting edge technology
32
Rough Times for RoughTerrain Forklifts?
34
VNATruck becomes AGV
35
TR626i/TR632i: The Industry’s most powerful Heavy Terminal Tractors
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Robust 4Way Trucks for Bright Steel Handling
38
Innovative Household Appliance Clamps
39
Accesoires
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Attachments, Tyres, LAN/WLAN, Scanner, Particulate Filters, Cabines, Seats etc. Hyster lifetime costs attract Katoen Natie
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Pallet Stacker in Standard and Special Customised design
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BYD brings low cost green efficiency to European lift truck market
FE-Battery and capacities up to 3.5 t will be the first data this Chinese manufacturer revealed.
Javier Contijoch is aiming for a CE-certification for the lift trucks. Dealer network will be established at the beginning of 2014. This maker of rechargeable batteries is en tering the European forklift truck market. The compamy offers lift trucks with a self developed FeBattery (Lithium Iron Phos phate) which offers truck owners emission free operation and also significantly lower costs when compared to the conventional lead acid technology. The BYD Fe battery consumes around 40% less electricity than an equivalent lead acid battery while offe ring the following additional benefits: I Extraordinarily long life cycle (4000 cycles which is equivalent to 10 years of normal 1 shift operation) at nominal service tem peratures I High charge efficiency (98%) I Maintenance free. No messy electrolyte refilling needed First models will be I 2.0 and a 2.5 tonne capacity electric counterbalance forklift trucks which, with a unique standon operating position and excellent safety performance, are some of the most operatorfriendly fork lifts on the market, suited for a wide ran ge of applications; and I a 2 tonne capacity electric pallet forklift featuring environmental protection, safe ty, high efficiency, reliability and comfort designed for the main application of sto rage and block stacking, as well as truck loading and unloading.
BYD Auto, already active in Europe from its Rotterdam headquarters in the pure elec tric bus and taxi markets, is planning to enter five European countries with its lift trucks in 2013 and early 2014 – Nether lands, Belgium and Luxemburg followed by Germany and France. The company em ploys 180,000 people worldwide. Warren Buffett’s Berkshire Hathaway owns a 10 % share. BYD has 11 major manufacturing and R&D facilities in China. Javier Conti joch, who joined BYD after years in auto motive sales and marketing management positions and 10 years in the logistics sec tor, adds: “Lift truck operators and the dealers who serve them should be looking closely at the BYD range. It doesn’t just
Drivers compartment with pretty much space.
First glimpse of the warehouse-range.
offer total environmental friendliness but substantial and immediately accessible operating cost savings when compared to the conventionallypowered machines. BYD is going to be a major force in the Euro pean lift truck market.” Pictures: STW
info BYD NL3047 AT Rotterdam Tel. +31 102070888 www.byd.com
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STAPLERWORLD EUROPE 01-2013
strengthens product portfolio in various segments TVH – Group Thermote & Vanhalst is the world’s largest manufacturer-independent provider of spare parts for lift trucks and other industrial equipment. The Belgian family-owned entity employs over 3,800 people and had in 2012 a turnover of mo re than EUR 800 million. The most impor tant activity by far is still the sales of spare parts. TVH sells parts and accessories for more than 250 brands of material hand ling and industrial equipment. Among these also many makes that have ceased operation in the course of the years of have been taken over by other companies. This is not limited to forklift brands but also includes segments such as telehandlers, aerial work platforms and sweepers and scrubbers.
6,000 orders and 18,000 order lines leave the premises to be delivered at the custo mer’s address 24 to 48 hours later. Two important developments underline the expansion plans of the Belgian family busi ness: I Increased in-house remanufacturing of electronic devices I Acquisition of the Italian forklift attach ment manufacturer CAM
Kristof Bolle, Director Sales of Industrial Equipment Parts & Accessories, explained during the visit of STAPLERWORLD that the demand for spare parts for ware house trucks, electric trucks and warehouse equipment is constantly increasing. Many electronic devices, for example for Linde, Jungheinrich, Still, Toyota, Crown and others are available for the aftermarket, but they may be too expensive as new components to equip used machines with.
In addition to the sales of parts, TVH is also very strong in the rental market for forklifts and access equipment. The acquisition of Gunco and more recently of the German company Mateco gave a huge boost to the rental activities. At present, the rental fleet of TVH contains 14,500 telescopic, scissortype and articulating boom lifts. TVH Parts sells to the end-user market in Belgium, but in the rest of the world TVH’s customers are mainly resellers, repair shops and rental companies. The spare parts ran ge currently includes 20 million known re ferences and holds 500,000 items perma nently in stock. To accommodate this stock, TVH has at its disposal some 100,000 m² of storage space. Every day, no less than
Every electronic engineer specializes in 1 make. This way TVH is creating experienced make specialists.
Electronics Department in Waregem. 55 employees are working in a stateof-the-art electronic laboratory covering an area of over 3,5000 square meters To solve this shortage, TVH again treads its own very successful ways. This refers to the remanufacturing of electronic controllers, cards, displays, joysticks and high-frequen cy chargers. These devices are all remanu factured at the headquarters in Waregem, by a team of 55 employees in a highly ad vanced electronics laboratory, covering an area of about 3,500 square meters.
The first step is to examine existing devices. These devices are dismantled, measured and studied extensively into every detail. The R&D engineers then reverse-engineer the circuit diagrams and make a bill of ma terial. Once this is finished, they will start to develop a computerized tester to fully test the functionality of that electronic device.
The remanufactured parts come with the same standard warranty as other TVH parts. The company is able to offer exchange parts or a repair service (repair of customer part) of widespread brands like Toyota, Linde, Jungheinrich, Still, Curtis, PG Drives, Sevcon, GE, Zapi, Kollmorgen and many other Eu ropean and US manufacturers.
Once completed, the R&D department hands over the schematics and tester to the elec tronic engineers in the workshop. From that point on, TVH is able to remanufacture and repair these electronic devices.
Every year, over 25,000 electronic devices are remanufactured by TVH’s electronic de partment. The customer helpdesk is available in mul tiple languages. These experts also guide the customers through the installation and troubleshooting. “Communication with our customers,” says Electronic Department manager Lorenz Verfaillie, “puts us in an ideal position to hear, see and observe what is going on on the market.” “The electronic devices business is a very forward-looking one,” says Kristof Bolle, “since the usage of electronic devices is ri sing constantly.” Furthermore, TVH has been appointed by Curtis as Authorized European Service & Repair centre and also became a distributor of globally active controller manufacturers like Sevcon, Curtis and PG Drives.
One of the electronic engineers repairing a Zapi AC controller.
STAPLERWORLD EUROPE 012013
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View of TVH headquarters based in Waregem / Belgium
CAM-attachments strengthen product portfolio TVH has 20 000 customers around the world – a huge number ranging from one man operation businesses to outlets and subsidiaries from all major manufacturers. These customers are specialized in the re pair of forklifts. They often get questions from their own customers not only to repair and service the lift trucks, but also to offer not only new tyres, forks, seats, etc..., and also hydraulic attachments. And that’s where CAM, founded in Grig nasco in northern Italy more than 40 years ago, enters the stage. This company initi ally focused only on the Italian market. In 2009 a distribution agreement with TVH marked the start of the successful collabo ration. Three years later, TVH acquired the company. Now, CAM produces the attach ments and TVH sells them. CAM has im proved its market position in key European countries such as Germany, GreatBritain, France, Russia and others. Total sales of CAM have increased the last 3 years. Every year the business grew with 30%. Overview of the production program: I Sideshifters from FEM class 1 to 4 (2,500 to 12,000 kg) I Fork positioner with/without sideshifter (2,500 to 12,600 kg) I Multifork positioners (1,600 to 2,600 kg) I Rotator with/without sideshifter (1,000 to 7,000 kg) I Bale clamps (rotating/nonrotating) I Fork clamps I 180°/360° rotating clamps I Carton clamps I Paper roll clamps I Pushpulls I Special attachments such as jibs, booms, load extenders etc. All attachments are produced at the facto ry located in Marano Ticino (Novara) in Italy where currently 30 people are employed. Core skills such as welding, assembly and testing remain in the company. Manage ment, sales, accounting and component manufacturing are outsourced – either to the parent company or to TVHcertified suppliers.
Most standard attachments are available from stock, special designs or particularly large attachments are exclusively custom made and can be delivered within 12 to 16 weeks. TVH`s staff of specialists assists du ring the installation, adjustment and modi fication.
info www.tvh.com www.camattachments.com
CAM attachments are characterized by their modular design, bolted forks and particu larly compact dimensions, all of which resul ting in an increase of the residual capacity of the lift truck. The current spectrum (1 to 6 tons), in addition to the volume segment, extends into larger payload categories up to 12,000 kg. Kristof Bolle views this seg ment as evergrowing and therefore CAM needs to be wellpositioned. Especially the sideshifters and rotators, fork positioner and clamps for the beverage and pa per industry already play a major role in the pro gram – more segments are currently being ac tively developed, inclu ding the technically challenging paper roll clamps. Pictures: TVH
Fork Protection for Special Applications Very often, de licate goods need to be transported directly on the forks. When using standard forks, parts can easily become scratched or da maged. Grippfix or polyurethane cladding minimizes such damage. Both materials are extremely resistant to cutting or abrasi on and furthermore prevent the goods
from sliding off (Grippfix even under wet conditions). Also noise from the transport of metal goods can be reduced. Customers may choose bet ween a fixed (bonded) cladding on the fork resp. fork extension and a re movable protective shoe. I According to the application, legal de mands need to be fulfilled: I Hygiene demands in the food and che mical industry I Safety laws for transport in hazardous areas For this, brass or stainless steel cladding is the perfect solution. A fixed cladding of 4 mm is applied on the fork blade or – if desired – on the whole fork. Advantages: Simple cleaning, safety against dirt and bacteria, spark proof when contacting the load or the ground. Thus, safety risks can be avoided efficiently. A further option for high safety is DuplexCladding, using two different materials: An outer material as
well as a different coloured inner material at the underside of the fork. Wear mainly occurs underneath the forks. As soon as the cladding is reduced to the minimum 1 mm thick, the fork needs to be replaced and the cladding renewed (EN 1755). Previously, wear could not be determined visibly. Regular, daily measuring is time consuming and requires special measu ring tools and knowledge. As soon as the outer cladding is worn away, the inner cladding becomes visible. By using mate rials of different colours (e.g. brass / stain less steel), wear can be determined imme diately. Pictures: Vetter info www.vetterforks.com
“OK
Innovation ist lebensnotwendig, aber bei Manitou haben technische Errungenschaften stets einen praktischen Nutzen, der meinem Team weiterhilft! “
MI SERIE
Die neue MI-Reihe mit ihrer schlanken Silhouette und den abgerundeten Kanten zieht gewiss die Blicke auf sich. Doch dieses innovative Design ist gleichzeitig bedienerfreundlich. Die geräumige und schöne Fahrerkabine bietet ein angenehmes und sicheres Arbeitsumfeld. Insgesamt bietet Ihnen der neue MI optimale Bedingungen für effizientes Arbeiten, den ganzen Tag lang.
Finden Sie den für Sie zuständigen MANITOU-Händler unter: www.manitou.com
Frank Neugebauer, Braunschweig I DirkHans Frobese, Braunschweig
STAPLERWORLD EUROPE 012013
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Industrial trucks for use in potentially explosive areas – placing on the market in compliance with Directive 94/9/EC Industrial trucks are used for handling con tainers with hazardous substances, inclu ding transport in their storage areas or for transport in filling and mixing plants. In such areas, gases, vapours, mist or dust may escape both under normal conditions and in the event of failures. When these substances get into contact with ambient air, they form explosive gasair or dustair mixtures, i.e. a potentially explosive atmos phere. This atmosphere may ignite in the presence of hot surfaces, hot exhaust ga ses, impact and friction sparks at mounted electrical and nonelectrical parts, or as a result of electric sparks or electrostatic di scharge. To prevent explosions in a poten tially explosive atmosphere, industrial trucks are operated as explosionprotected equip ment. Measures that have to be taken to avoid potential sources of ignition at the truck itself are listed in the European EN 1755 standard. The requirements for placing explosionprotected equipment on the Eu ropean market are regulated by Directive 94/9/EC (ATEX Directive). The present paper explains the interaction between Directive 94/9/EC, other EC Direc tives and EN 1755 in connection with the placing on the market of explosionprotec ted industrial trucks. The paper in particular wants to show when an explosionprotec ted industrial truck should be inspected by a notified body in compliance with Directi ve 94/9/EC.
Dicrective 94/9/EC The ATEX Products Directive 94/9/EC [1] defines the rules and regulations for pla cing explosion protected equipment and protective systems as well as safety, cont rolling and regulating devices on the mar ket. This Directive is the first directive to also include nonelectrical explosionpro tected equipment on a European scale. Friction brakes, hydrodynamic couplings or hydraulic systems, may, for instance, pro duce an ignition risk when allowed to heat excessively. In its Annex II, Directive 94/9/EC specifies the essential health and safety require ments that producers of explosionprotec ted equipment have to observe, compli ance with which has to be proved in the form of conformity assessment procedures as set out in Article 8 of Directive 94/9/EC. Current technological knowledge must be applied without delay and as far as possib le. This means that equipment must be manufactured in compliance with gene rally accepted codes of practice and on the basis of the latest version of standards. Eu ropean Standards that have been harmo nised with respect to one or more than one EC Directive(s) may be presumed to conform with the requirements of the cor responding Directives. They are published in the Official Journal of the European Uni on.
The placing on the market in compliance with EC Directives As of 30 June 2003, equipment, protective systems as well as safety, controlling or re gulating devices have had to conform with Directive 94/9/EC to be able to be placed on the market. In Germany, this European Directive was translated into national law with the 11th Ordinance relating to the Equipment and Product Safety Act (11th GPSGV) [2]. On 8 November 2011, the new Product Safety Act [3] transposed the pre vious 11th GPSGV into the 11th Ordinance relating to the Product Safety Act 11th ProdSV [4]. Industrial trucks must, in addition, also comply with all other relevant EC Directives, such as the Machinery Directive 2006/42/ EC [5] or the EMC Directive 2004/108/EC [6]. An explosionprotected industrial truck may only be placed on the European mar ket by one manufacturer who has to assu me general responsibility. The company/ person placing a product on the market need not necessarily be the manufacturer of that product, but that company/person must comply with all obligations set forth in the relevant EC Directives for that pro duct and must be based in the European Union. This is due to the fact that in the European Union, only the company/person placing a product on the market can be held liable in connection with liability and
References [1]
[2] [3] [4] [5]
[6]
Directive 94/9/EC of the European Parliament and the Council of 23 March 1994 on the approximation of the laws of the mem ber states concerning equipment and protective systems intended for use in potentially explosive atmospheres. Official Journal of the European Union, vol. 37, No. L 100/1 of 19 April 1994. 11th Ordinance on the Equipment and Product Safety Act (Explosion Protection Ordinance 11th GPSGV) of 6 January 2004 (Federal Law Gazette I p. 2), replaced by [4]. Act on making products available on the market (Product Safety Act ProdSG) of 8 November 2011, Federal Law Gazette I p. 2179. 11th Ordinance on the Equipment and Product Safety Act (11th ProdSV Explosion Protection Ordinance) of 12 December 1996 (Federal Law Gazette I p. 1914), as amended by article 21 of the act of 8 November 2011 (Federal Law Gazette I p. 2178). Directive 2006/42/EC of the European Parliament and the Council on machinery, and amending Directive 95/16/EC (recast) of 17 May 2006 (OJ No L 157 of 9 June 2006, pp. 24). Implemented in Germany with the Ninth Ordinance on the Product Safety Act (Machinery Ordinance 9th ProdSV) of 12 May 1993 (Federal Law Gazette I p. 704), as amended by Article 19 of the Act of 8 November 2011 (Federal Law Gazette I p. 2178). Directive 2004/108/EC of the European Parliament and the Council of 15 December 2004 on the approximation of the laws of the Member States relating to electromagnetic compatibility and repealing Directive 89/336/EEC. OJ No. L 390/24 of 31 Decem ber 2004. Implemented in Germany with the law relating to the electromagnetic compatibility of equipment of 26 February 2008 (Federal Law Gazette I p. 220), as amended by clause 3 of the law of 29 July 2009 (Federal Law Gazette I p. 2409).
1 originally published in Technische Sicherheit Bd. 2 (2012), No. 6, page 3438, SpringerVDIVerlag GmbH & Co. KG, Düsseldorf, ISBN 14349728.
Vita
and EN 17551
Frank Neugebauer
Dr.-Ing. Dirk-Hans Frobese
PhysikalischTechnische Bundesanstalt Bundesallee 100 38116 Braunschweig Germany phone: +495315923536 fax: +49531592693536 frank.neugebauer@ptb.de
PhysikalischTechnische Bundesanstalt Bundesallee 100 38116 Braunschweig Germany phone: +495315923420 fax: +49531592693420 dirkhans.frobese@ptb.de
legal issues. In the paragraphs below, this paper will always use the term “manufac turer” wherever it actually addresses the “manufacturer or his authorised represen tative within the Community”. Whoever subjects a product that has already been placed on the European Market to major modifications, thus creating a new product (e.g. a nonexplosion protected industrial truck is converted so that it be comes an explosionprotected industrial truck) becomes the manufacturer of that product and will consequently be respon sible for the complete “new” product. This means that only one CE marking has to be affixed on the explosionprotected indust rial truck and only one declaration of con formity has to be issued. Any other mar king on the industrial truck has to be removed. Exempted from this regulation is the CE marking of equipment that is used inside the industrial truck and that carries a CE mark to comply with Directive 94/9/EC or other EC Directives.
Fig. 1: Possible measures for industrial trucks
Frank Neugebauer, Braunschweig I DirkHans Frobese, Braunschweig
STAPLERWORLD EUROPE 012013
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There are two options for placing explosi onprotected industrial trucks on the mar ket: I The explosionprotected industrial truck is developed, designed and manufactu red by the manufacturer as an explosion protected product, however the manu facturer may make use of the services of third parties, who are commissioned to perform certain steps in the production process and thus act as an "extended workbench". In that case, the manufac turer is responsible for the outsourced production processes. The manufacturer prepares the declaration of conformity and affixes the marking. I An industrial truck that had originally not been intended for use in potentiallyex plosive atmospheres is equipped with the safety features or modified for explo sion protection requirements by a conver ting company. Any nonexplosion pro tected parts are removed and replaced with explosionprotected ones. The con verter places the explosionprotected industrial truck on the market, prepares the declaration of conformity for the complete piece of equipment (conformi ty with all relevant directives) and affixes the marking. The converter also has to remove the marking that had been pro vided by the manufacturer of the original piece of equipment, because it does now no longer apply. If, for instance, the user of the industrial truck commissions the conversion of the industrial truck for explosion protection re quirements, the user becomes the manu facturer with all consequences that follow from this fact. Details of the notion of “ma nufacturers of industrial trucks” can be found in a VDMA position paper [7].
Conformity assessment The conformity assessment of explosion protected equipment depends on the equip ment group and the equipment category of that equipment. Equipment group I ap plies to equipment intended for use in un derground parts of mines and surface ins tallations of said mines. Equipment group II applies to equipment intended for use in other places liable to be endangered by explosive atmospheres. Directive 94/9/EC uses the term equipment category as a measure of the absence of ignition sources. In equipment group II, ca tegories 1, 2 and 3 are listed: I Category1 equipment is characterised by a very high degree of safety, which makes it suitable for use in areas in which potentially explosive atmospheres are present continuously, for long periods or frequently (use in zones 0 or 20). I Category2 equipment is characterised by a high degree of safety, which makes it suitable for use in areas in which po tentially explosive atmospheres are likely to occur (use in zones 1 or 21). I Category3 equipment is characterised by a normal degree of safety, which ma kes it suitable for use in areas in which potentially explosive atmospheres are unlikely to occur or, if so, only infrequent ly and for a short period (use in zones 2 or 22). In view of the special hazard situations and the protective measures to be taken with equipment category 1, explosionprotec ted industrial trucks cannot fall into this category.
The requirements for the conformity as sessment procedure for category2 equip ment are set out in Article 8 (1) letter b) of Directive 94/9/EC, in which I (i) requires for electrical equipment and internal combustion engines an EC Type Examination Certificate and monitoring of the quality assurance system by a no tified body, and I (ii) requires for other equipment that the manufacturer assess himself (manufac turer selfassessment) with internal con trol of production, the related documen tation having to be deposited with a notified body. Industrial trucks consist of different electri cal and nonelectrical pieces of equipment and components, the assembly of which is defined in the ATEX Guidelines [8] as an assembly or equipment combined from dif ferent parts. In connection with “Fork lift trucks inten ded for use in potentially explosive atmos pheres”, the “Consideration Paper” of the Standing Committee of the Commission [9] points out for industrial trucks of cate gory 2 that the combined equipment (fork lift truck) is “neither electrical equipment nor another internal combustion engine”, provided the manufacturer ensures that no additional ignition risk can result from the combination of components. With internal control of production and by depositing the technical documentation with a noti fied body, the manufacturer in this case complies with the requirements of Directi ve 94/9/EC. In particular the assessment of assemblies in which a wide range of equipment of types of protection Increased Safety “e”,
References [7] [8]
[9]
[10] [11] [12] [13]
VDMA position paper “VDMAPositionspapier Flurförderzeuge für den Einsatz in explosionsfähiger Atmosphäre”, status: 04/02/2011, http://www.vdma.org/wps/portal/Home/de? WCM_GLOBAL_CONTEXT=/vdma/Home/de Guidelines on the application of Directive 94/9/EC of the European Parliament and the Council of 23 March 1994 on the appro ximation of the laws of the member states concerning equipment and protective systems intended for use in potentially explo sive atmospheres. 3rd edition June 2009 Consideration Paper des Standing Committee der Kommission “Fork lift trucks intended for use in potentially explosive atmos pheres”. http://ec.europa.eu/enterprise/sectors/mechanical/ documents/guidance/atex/standingcommittee/forklifts/index_en. htm. DIN EN 1755:2010: Safety of industrial trucks Operation in potentially explosive atmospheres Use in flammable gas, vapor, mist and dust; German version EN 1755:2000+A1:2009, Beuth Verlag, Berlin. DIN EN 600790: 2011: Explosive atmospheres Part 0: Equipment General requirements, German version EN 600790:2009, corrigendum to DIN EN 600790:201003, Beuth Verlag, Berlin. DIN EN 134631:2009: Nonelectrical equipment for use in potentially explosive atmospheres Part 1: Basic method and requi rements, Beuth Verlag, Berlin. DIN EN 1834 Parts 1 to 3:2000: Internal combustion engines for use in potentially explosive atmospheres, Beuth Verlag Berlin.
Flameproof Enclosure “d” or Intrinsic Safe ty “i” or combustion engines is used can leave much room for interpretation regar ding additional ignition risks. This room for interpretation has in the past often led to situations in which no EC Type Examination Certificates were issued for category2 in dustrial trucks, although this did not al ways appear to be justified. Negative expe rience has led to some rethinking, and today a more differentiated approach is taken in this matter. Today’s view is that an EC Type Examination Certificate is required for the complete assembly, if there are ad ditional electrical ignition risks, or ignition risks concerning the combustion engine, when equipment is assembled. For manually operated pallet trucks of ca tegory 2G, no type examination as defined by Directive 94/9/EC is made, because no additional ignition risks have to be expec ted to result from assembling the equip ment. Even if a weighing device is attached, an EC type examination is not necessarily required for the “industrial truck” assem bly. Irrespective of what has just been said,
a separate EC Type Examination Certificate would be necessary for the weighing de vice, if it is electrical category 2 equipment. In addition to the EC type examination, the manufacturer must have a quality assu rance system in place, which must be as sessed by a notified body. For equipment category 3, Directive 94/9/ EC does not require the involvement of a notified body; it places the responsibility on the manufacturer. Individual explosionprotected industrial trucks may, irrespective of the equipment category, also be subjected to EC unit veri fication by a notified body in accordance with Article 8 (1) letter d) of Directive 94/ 9/EC. A European standard that appeared in the year 2000 already defined the specific re quirements for explosionprotected indus trial trucks. Since then, this EN 1755 stan dard [10] has been amended with a first supplement. The standard describes the
specific measures that have to be taken for avoiding ignition risks in connection with industrial trucks, and it makes reference to various European standards [11 13] in which basic requirements are defined for explosionprotected equipment. Figure 1 illustrates possible measures for avoiding ignition risks in connection with industrial trucks.
Examination of industrial trucks and documentation If an EC type examination is justified for the complete industrial truck, a completely as sembled specimen is used as an example for the required testing in accordance with EN 1755. This also includes checking the documentation, which must consist of a description and the relevant drawings, for compliance with the items listed in the standard and with the specimen itself. Ex amination also involves: I a visual and functional examination of the electric and hydraulic functions; I temperaturerise measurements for the hydraulic system, the brake system and
Frank Neugebauer, Braunschweig I DirkHans Frobese, Braunschweig
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Counterbalanced Lifttrucks
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the prime movers, the systems being loa ded until a steady state is reached or the temperature monitoring device res ponds; I measurement of the surface resistance and leakage resistance of rubber and plastic elements to earth, and examina tion of the potential equalisation among the metallic components, I assessment of equipment and compo nents that come with their own EC Type Examination Certificate (e.g. flameproof enclosures, lamps, internal combustion engines). If explosionprotected industrial trucks are driven by a internal combustion engine, this engine must also be examined in com pliance with EN 1834, an EC type examina tion by a notified body being required for equipment category 2. Based on EN 1755, and possibly additional standards, the examination documents ha ve to specify the extent to which the routi ne test that is required during the produc tion process has to be performed and what measuring equipment and auxiliaries have to be used. After successful assessment of the explosi onprotected industrial truck, the manu facturer prepares the EC Declaration of Conformity, which he hands out to the customer together with the industrial truck and the instructions for operation.
Technical examples of industrial truck equipment The manufacturer or the converter of an industrial truck decides whether additional ignition risks may result from the assembly of equipment that has already been type approved so that a notified body has to become involved for the “industrial truck of category 2” assembly. Whether or not all ignition risks are in this case detected very much depends on the available explo sion protection knowledge. The examples that are listed below are to highlight some technical designs and possible problems as well as relevant information. I Mounted parts that come with an EC Ty pe Examination Certificate as a compo
nent (“U” certificates) must be exami ned together with the industrial truck by a notified body; an EC type examination becomes obligatory for the industrial truck. I If a commercial internal combustion en gine e.g. Diesel engine is equipped in a workshop with a conversion kit, which carries an EC Type Examination Certifica te for explosion protection, this internal combustion engine does not automati cally become an “explosionprotected internal combustion engine”. In compli ance with Directive 94/9/EC, this engine must be subjected to a type test regar ding compliance with the temperature class and the required temperature mo nitoring features. It must also be de monstrated that the necessary flame ar resters and spark arresters are suited for reliably preventing flame or spark trans mission into the surrounding potentially explosive atmosphere. If the necessary parameters are complied with, an EC Ty pe Examination Certificate is issued for category2 combustion engines. I Explosionprotected industrial trucks that are driven by an explosionprotected in ternal combustion engine e.g. Diesel en gine must be examined in respect of the installation conditions and in respect of the operating conditions that are speci fied for the Diesel engine. This can have an effect on the required temperature monitoring features and means that an EC type examination is required for the industrial truck. I If an industrial truck is fitted with win dows made from plastic that can be charged electrostatically [11], the indus trial truck is not suited for use in poten tially explosive atmospheres even if a note “only clean with a moist cloth” draws the attention of the user to the risk of electrostatic charging. This is ac cepted only, for instance, for light fixtu res that are permanently installed in the ceiling of a room and can neither be electrostatically charged or discharged as a result of unintentional contact. Plas tic parts of an industrial truck cannot be reliably prevented from becoming elect rostatically charged. When the EN 1755 requirements are complied with, the ma nufacturer can himself assess this igniti
on risk and take the necessary protection measures – the need to have a notified body perform an EC type examination cannot be derived from these conditions alone. I If an operational friction brake comes with a temperature sensor in the brake lining, the brake lining cannot be repla ced without a temperature sensor. Even if a temperature sensor should be subse quently fitted, the safety requirements are not complied with, unless a new EN 1755 examination is made. Safety measures must be taken for cases in which the fitted temperature sensor might be destroyed by the braking ac tion or is affected by a series fault. In accordance with Directive 94/9/EC, a friction brake has to be classified as “another device” and assessed by the manufacturer himself, i.e. an EC type ex amination is not necessarily required. I Brakes with a flameproof enclosure, on the other hand, have to be subjected to experimental testing for nontransmissi on of internal ignition and to a test for determination of the maximum explosi on pressure. The required explosion tests can normally not be performed by the manufacturer himself. Regarding the protection level, these brakes compare to an electrical enclosure of Flameproof Enclosure "d" type of protection [14]. The test should be made by a test orga nisation with sufficient experience in ex plosion tests. This can however not be construed to be a legal basis for the need of an EC type examination both for the (nonelectrical) flameproof brake and for the explosionprotected industrial truck. If the brake forms an integral part of an electrical flameproof enclosure, e.g. part of an electric drive, an EC type examina tion must be made for the flameproof enclosure as an electrical piece of equip ment. If additional ignition risks, such as excessive heating, follow from the as sembled equipment, an EC type exami nation should also be made for the as sembly. I During operation, hot surfaces or me chanically produced sparks may occur on purely mechanical mounted parts, such as the mast, barrel gripper, hydraulicfluid tanks, which can then ignite a potentially
References [14] DIN EN 600791:2008: Explosive atmospheres Part 1: Equipment protection by flameproof enclosures “d”, German version 600791:2007; 2007, corrigendum to DIN EN 600791:200804, Beuth Verlag Berlin. [15] DIN EN ISO/IEC 8007934:2012: Explosive atmospheres Part 34: Application of quality systems for equipment manufacture.
explosive mixture. Electrostatic discharge may also occur inside the oil container, if the flow velocity of the hydraulic fluid reaches a certain level. This may, in par ticular, be the case when insulated metal elements, such as filters, are installed inside the hydraulic circuit. This explains why the ignition risk has to be assessed for all mounted and installed parts. De tailed information may be obtained from the EN 13463 series of standards (as amended). What has been said above for friction brakes, also applies in this case: the need for an EC type examination for the complete industrial truck cannot be derived on this basis alone. I Electric motors with their own EC Type Examination Certificate are tested and certified for defined electrical designs and ambient conditions (e.g. duty type and monitoring system). When motors are installed in the confined space of in dustrial trucks, the ambient conditions differ from the test conditions, because the frame elements and the housing co ver of the industrial truck only provides for limited cooling, and this may lead to an inadmissible temperature rise. As a result, the limiting temperatures may be exceeded, and the electronic system for monitoring the motors may trip prema turely. These additional ignition risks in connection with electric motors that ha ve already been certified have to be con sidered and assessed as part of an EC type examination. The above examples show that various ad ditional ignition risks have to be accounted for when assembling an explosionprotec ted industrial truck. If a category2 indust rial truck is exclusively composed of me chanical equipment and attached parts, as is for instance the case with a manually operated pallet truck, the manufacturer is normally able to assess the ignition risk himself. An obligation for performing an EC type examination cannot be inferred. If, however, an industrial truck is equipped with electrical equipment or internal com bustion engines e.g. Diesel engine, this equipment is itself subject to an EC type examination. If additional ignition risks cannot be excluded for this equipment as a result of the assembly of the equipment, an EC Type Examination Certificate for the complete industrial truck is justified in ac cordance with the Guidelines pertaining to Directive 94/9/EC [8].
Control of production
Summary
In accordance with Directive 94/9/EC, the manufacturer must take measures for pro duction control as part of his quality ma nagement system. Whenever the equip ment has been subjected to an EC type examination, Directive 94/9/EC requires the participation of a notified body, i.e. the notified body reviews the production con trol measures as part of an audit. This ap plies to explosionprotected industrial trucks of category 2 for which equipment assem bly has produced an additional ignition risk for electrical equipment and/or the com bustion engine so that the manufacturer has a notified body perform an EC type examination. The special production con trol measures required for explosion pro tection are set out in EN 8007934 [15].
Explosionprotected industrial trucks are equipment within the meaning of Directive 94/9/EC. The manufacturer of explosion protected industrial trucks may place this equipment on the EU market only if he has fulfilled the requirements of Directive 94/9/ EC and of all other relevant Directives; he must also go through the conformity as sessment procedure that is set out in Direc tive 94/9/EC. For explosionprotected in dustrial trucks of category 2 that may be affected by additional ignition risks in con nection with electrical equipment and combustion engines as a result of equip ment assembly, an EC type examination must be made by a notified body. Explosionprotected industrial trucks must be clearly marked, and there may only be one responsible manufacturer for the com plete unit. Dual marking by two or more manufacturers is not accepted. The mar king must comply with all relevant EC Di rectives.
info Dr.Ing. DirkHans Frobese PhysikalischTechnische Bundesanstalt Fachbereich 3.4 „Grundlagen des Explosionsschutzes“ Leiter der Arbeitsgruppe 3.42 „Gemischausbreitung und Explosionsvorgänge“ Bundesallee 100 I 38116 Braunschweig I Germany Fon: +49 (0)531 5 923420 I Fax: +49 (0)531 5 923405 oder +49 (0)531 69 3420 email: dirkhans.frobese@ptb.de I www.ptb.de, www.explosionsschutz.ptb.de
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Federal German Ecodesign Award The Hamburg based company has won the prize for its RX 70 Hybrid forklift truck in the category “Product” for excellent ecologic design covering the complete life cycle awarded for the first time by the Fe deral Ministry of Environment and the Fe deral Environment Agency.
Still offers custommade solutions for internal logistics worldwide imple menting the intelligent interplay of forklift trucks, warehouse equipment, software and services. What the foun der of the company Hans Still had ini tiated in 1920 with a great deal of creativity, entrepreneurial spirit and quality has quickly developed to be a globally renowned and strong brand. Today, over 7 000 qualified employees work in development, production, sa les and service every day to meet the customer requirements around the world. The key to corporate success is a highly efficient product range sco ping complete solutions especially de signed for large and small companies in individual industries as well as com puterbased software applications for logistics to provide effective warehouse and materials management.
The prize was presented at the award cere mony in the Federal Ministry of Environ ment to the Chairman of the Management Board at STILL and the Director of Corpo rate Communications of the company Matthias Klug by the Parliamentary Secre tary of State Ursula HeinenEsser together with the President of the Federal Environ ment Agency Jochen Flasbarth. The prize honours companies for products designed to especially avoid any harmful environmental effects. “The Federal Ecodesign Award is of special value to us, because it honours not only the individual product but the whole under lying philosophy.” says Knoef. “Ecologic responsibility is an elementary component of our corporate mis sion and it compri ses production pro
cesses, product use as well as recycling of the product. Winning the award tells us that we are on the right way.” And indeed, the RX 70 Hybrid from STILL the optical design has been developed to gether with the internationally successful design agency ´Teams Design` is a prime example for an ecologically responsible
product philosophy. The truck is fitted with a dieselelectric drive and is propelled by energy from a diesel tank as well as by energy from an electric energy storage system, so called Ultracaps. These capacitors are capable of storing large amounts of energy developed when brakes are applied and release it when needed. This reduces the work load of the com bustion engine which will therefore consume less fuel and significantly reduce CO² emissions – by up to 20%. This makes it by far the most economic truck of its class. Ecofriendly production processes, the energy saving programme BlueQ which is available as a standard on all STILL counter balance trucks as well as the fact that 95% of the materials used for the RX 70 Hybrid can be recycled, round off the future oriented product concept of the awarded truck.
The Federal Ecode sign Award is awarded in three categories: “Product”, “Con cept” and “Young Talent”. The panel of re nowned design and ecology experts elected the winners of the individual categories from a total of 140 nominees. Environment minister Peter Altmaier was the patron of the award ceremony. He opened the event with a welcome speech in which he compli mented the companies on the unique combi nation of the aspects economy, environment res ponsibility and design.
compact sturdy durable
HALL 1 – BO
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Photo: STILL GmbH info www.still.de
Stöcklin Logistik | www.stoecklin.com
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VNA-Market still going strong – what are the major Trends for 2013? STAPLERWORLD the FORKLIFTMAGAZINE spoke with Steve Ridgway, Brand Manager Yale EMEA, NACCO Materials Handling Li mited about actual developments. We have learned the VNA market in Europe features about 1600 machines in a normal year, do you agree to this market size and what are the main markets (countries) for YaleVNA-trucks? S. R.: We believe the market to be more like 2500 for Europe, main market is Germany, then UK, France, Turkey, Italy then Holland. RFID, inductive and mechanical guidance are on the market – where do your customers see the most benefit? S. R.: Integration between electronics and computer programming allow for more in telligent systems. The Yale MTC Series is able to travel at 12 km/h on a wire guidance system in the right application RFID to gether with wire guidance can be signifi cantly beneficial.
VNA trucks can touch the 19.000 mm lifting (grip height) is that a trend or do remain most of the trucks in the 10.000 mm range? S. R.: There will always be an extreme, buil ding above 15 meters external dimension begins to be more costly and complicated to acquire planning permission, there are projects which are higher, but Yale see mo re of these requests outside of Europe. Nacco has created a major investment in the VNA-production at Masate, what is the intention of this investment? S. R.: We were working in a smaller space and wanted the ability to increase production as we had to run double shifts to keep up with demand. Vertical space was also limited our new production line has over 18,000mm ceiling clearance and the ability to step up production and ma nufacture a lot more units in a single shift with the opportunity to switch on a second shift as an when needed. Logistic business is booming, will VNA-trucks be one of the future solutions for your customers or can shuttle (Jungheinrich, Dambach, Still etc.) systems and rail guided storage and retrieval units take over? S. R.: VNA will always have its place as it provides the user with 100% selectivity of the pallets. VNA-trucks are special in many aspects how do you organize qualified service throughout Europe? S. R.: Compulsory service training is carried out in the Factory in Masate rather than European training centre in Holland. Fac tory personnel are also on hand to sup port the dealer with installation at the customer’s site. Are VNA-trucks something the average Yale-dealer can handle, how is he supported? S. R.: A team of Yale field service engineers and a factory resident service support team are at hand should a dealer require assis tance.
What will the next generation of your products feature, when are we going to see them, will CeMAT show 2014 be the place? S. R.: We are not planning any new VNA product introductions in 2014.
info Steve Ridgway, Brand Manager Yale EMEA Tel.: +44 7739612601 www.nacco.com, www.yale.com
True Quality
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Gabelstapler 10-52 t • Logstackers 9-28 t SVETRUCK Deutschland GmbH Rotenbrückenweg 24, DE-22113 Hamburg Telefon 040-713 757-0 Telefax 040-713 757-25 www.svetruck.de
Svetruck 184x245mm Donnerstag, 24. M
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Increased-power rated traction battery at Villeroy & Boch
The monitoring device collected 52 data sets over a period of 2 months, these were read out of the non-volatile store via Bluetooth. It looks like a standard electric forklift: The E 25 with increasedpower rated battery and around 23% more handling capacity. The tile division of Villeroy & Boch was hived off into an independent limited company (V&B Fliesen GmbH) on January 1, 2006. On July 1, 2007, Villery & Boch AG sold 51% of the V&B Fliesen GmbH to the Turkish ceramic manufacturer VitrA (Ecza cibasi Holding). In January 2011 the shares in V&B Fliesen GmbH held by the Eczacibasi Group were increased to a total of 75%. This makes Eczacibasi one of the largest tile manufacturers in Germany. In the field of sanitary ware, the company is the sixth largest manufacturer in the world with a volume of 6.2 million units.
At Villeroy & Boch, the new battery is being tested on a Linde E 25 (model series R336), alternating with a conventional 5 PzS 625 leadacid battery (625 Ah). The data from 52 charging cycles over the first 2 months are now available. With the 1285 TCSM battery (660 Ah), the forklift could be ope rated 23% longer on average with one battery charge, and the handling capacity per battery charge increased accordingly. This means the catalogue promise of an increase in handling capacity of 14% made by GNB Industrial Power was significantly exceeded. The data were recorded by pre cisely monitoring the battery using Batcom battery monitoring equipment, which can be read out using Bluetooth. All data can then be visualised on a PC. Dr. Kai Ruth, the product manager respon sible at GNB Industrial Power, values the high capacity and service life of the new battery, which is expected to exceed the standard of 1,200 cycles at 80% depth of discharge for PzS batteries in real use. And
At the Mettlach plant, 650 employees are involved in tile production. A fleet of 76 forklift trucks is used in production, the warehouse, logistics and for loading and unloading trucks. Linde retailer Jungbluth looks after the cus tomer, and together with GNB Industrial Power chose specifically this customer to put the new Tensor battery to the test in tough daytoday conditions. The vehicles are used in the Logistics department and work in threeshift operation six days a week. Logistic Manager Schleiß tested the new battery, which can be charged using existing HFchargers. Further test batteries have been “fielded out” around Europe for a wide range of different applications in order to collect more data.
Diagram of the last 30 cycles shown in the form of a graph.
Reading out the Batcom device at the test battery. the batteries have a lot to perform, since the Linde forklifts cover routes up to 1,000 m long loaded with pallets weighing 400/ 500 kg, and have to transport up to 1,000 pallets per day. If frequent intermediate charging is to be used, Ruth recommends electrolyte circulation and quotes an ener gy saving of 15% and a water saving of up to 75%. Photos: STW info GNB Industrial Power A division of Exide Technologies GmbH Marketing Germany and Export Tel. +49 (0)6042 81463 www.gnb.com
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RoRo Special Forklift Truck delivered to BLG Logistics Group
The RoRo special forklift truck transports the concrete segments, weighing 30 tons, on which the tripods are stored, and sets them down exactly underneath the tripods. Konecranes Lifttrucks and BLG Logistics Group joined spirits and experience for a special forklift truck. Its task will be the transport of concrete segments with a weight of 30 tons, which are required in Bremerhaven for storing tripods with a weight of up to 900 tons, threefoot steel foundation elements for offshore wind parks. The BLG Logistics Group, an international logistics provider with its registered office in Bremen and 15,000 employees worldwi de, develops customerspecific logistics solutions – including solutions for offshore wind park projects. For this purpose, the group of companies erects a central inter mediate store for tripods, threefoot steel foundation elements for offshore wind parks with a weight of up to 900 tons, on the “ABC peninsula” in Bremerhaven. Konecranes Lifttrucks has customized build height, load capacity, engine power and consumption of the new special forklift truck exactly to the requirements of the customer. The result is the special forklift truck SMV 321200 RoRo with a load capa city of up to 32 t at 1.200 mm load centre and very low build height of 2.950 mm. “The new special forklift truck is well able to move safely under the tripods and set down the concrete segments with precisi on. With its high acceleration values it also ensures efficient turnover on RollonRoll off ships“, says Jens Uwe Meier of Kone cranes Lifttrucks in Bremen and adds: “Due to the high motor performance we have specially designed the particulate filter as a double filter with a double exhaust system. The new special forklift truck for BLG may
therefore also be used in enclosed work shop areas – and protects the environment and our climate.“ The special forklift truck is also fitted with a Parker Load Sensing System complete with variable pump capacity for a lower fuel consumption and a reduced load on SMV 32-1200 RoRo with a load capacity of up to 32 tons and a very low build height of 2.950 mm meets the exact requirements of BLG Logistics Group.
Detailed description of the special forklift truck for BLG Logistics Group Type:
SMV 321200 RoRo
Load capacity:
32.000 kg at 1.200 mm load centre
Mast:
Duplex free lift
Lifting height:
3.100 mm
Build height retracted:
2.950 mm
Build height extended:
4.560 mm
Free lift:
1.550 mm
Mast tilting angle:
5°forward/10° backward
Engine:
Scania DC1258A EU Stage 3a
Hydraulics:
Parker Load Sensing System with variable pumps
EMC System:
An electronic overloadmonitoring and safety system controls motor, transmission and hydraulics.
CANBus:
ISO standardized field bus controls motor, transmission and cab
Special particulate filter:
Particulate filters for exhaust gases for freedom from particu lates as a double filter complete with double filter and doub le exhaust system for use in closed workshops – and protects the environment and climate
Due to its low build height the RoRo special forklift truck by Konecranes Lifttrucks passes underneath the tripods on the “ABC peninsula” in Bremerhaven. The three-foot steel foundation elements, weighing up to 900 tons, for offshore wind parks are placed into intermediate storage there by the BLG Logistics Group.
motor and system components. An elect ronic overload, monitoring and safety sys tem (EMC) controls motor, transmission and hydraulics. The driver’s cab is very er gonomically designed, with a high level of noise and vibration damping, turnable driver’s seat, heater as well as defrosting system. “The new special forklift truck is a top pro duct. We are pleased that we are the first to use this new type of Konecranes Lifttrucks in Germany. With its high load capacity and performance this special forklift truck assures and accelerates our production and logistics processes in the offshore terminal. Storage and turnover of the tripods are not possible without this special forklift truck”, says Matthias Witte, Senior Project Manager for the BLG De partment Wind Energy Logistics. As a spe cialist for automotive, contract and contai ner logistics the BLG Logistics Group has been a customer of Konecranes Lifttrucks for many years already and uses a.o. Reach Stacker and Heavy Load Stacker for carry ing loads of 16 to 52 tons. Pictures: Konecranes
info Konecranes GmbH 30853 Langenhagen, Germany Tel +49 (0) 511 77040 www.konecranes.de
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STAPLERWORLD EUROPE 01-2013
ADVERTORIAL
Mast profiles: Partnership from the very beginning It is clear that future lift truck generations will undergo considerable changes in de sign – in this regard we can think about the significant impacts that smaller and lighter lithium-ion-batteries could have. Regardless of future developments, the mast will remain of each truck. Hoesch Schwerter Profile (HSP), based in Schwerte in the Ruhr industrial area of Ger many and part of the Italian Calvi group since 2006, is on track to initiate a deve lopment that is primarily known in the automotive industry: Ever more frequently OEMs and their suppliers form partner ships right at the beginning of the design stage of new machinery and equipment.
Jürgen Mensinger, Technical Managing Di rector at HSP since mid 2012, is a professi onal when it comes to the production of special steel profiles for different applica tions. This becomes eminently clear during the meeting with Staplerworld. “In the past” he explains, “development was driven exclusively by the lift truck manufac turers, however, since the introduction of SE-|M|® I envisage HSP becoming an even stronger partner from the initial develop ment stages of new mast construction. Ul timately, we can offer customer-optimized solutions with regard to cross-section, tole rances and material grades. Compared to their cold drawn equivalents, the hot rolled and machined SE-|M|® profiles provide the great advantage that distortion (bow and
Calvi-Group/Hoesch Schwerter Profile Calvi Holding is a group of companies, which are located primarily in Italy, France, Germany and the USA. With 1,399 employees worldwide the Group generated sales of approx. € 314 million in 2012, of which EUR 107 million were accounted for by HSP. HSP employs 511 people. The materi als handling industry accounts for roughly for 70 % of HSP´s turnover. HSP manufactures hot-rolled, hot ext ruded and cold drawn special profiles.
twist) caused by heating during the process of welding them to form the mast is abso lutely minimal. This saves additional costs for straightening. The topic of tolerances is a key issue for Jürgen Mensinger and his team. Along with the tolerances for straightness the most important arguments for the manufacture of high-precision lift masts (up to heights of 17 m+) are the total combined chamber dimension tolerances of 0.2mm as well as the possibility to provide the flanges at a 90° +/-0.5° angle and the minimized tole rances of the outer radii. Thus, the profile specialists see themselves at the forefront of the development. In ad dition the SE-|M|® profiles are offered at
Hoesch Schwerter Profile GmbH D58239 Schwerte Tel.: +49 (0) 2304 1060 www.hoeschprofile.com
pricing under that of their cold drawn equi valents. Mensinger and his team with the support of Rostock University have initiated a pro gram to optimize the processing of mast profiles. ”Our intention is not only to pro vide the customers with samples and technical data”, he explains, “but to be a partner during the whole process of con ceptualisation and prototyping. We also work hand in hand for the first test masts and preproduction samples. We are, in fact, a partner of the first hour for every industrial truck manufacturer. Ultimately, in close cooperation with an Italian roller bearing manufacturer we can even supply a custom mast profile and bearing com bination for prototypes for field trials.” Mensinger wants not only to supply the steel in the correct length, quality and quantity, but also to ensure that the pro duction departments of the lift truck manu facturers can incorporate the high quality SE|M|® profiles faster and more efficiently in to their production processes. The “time tomarket” requirement especially for ware house and highstorage trucks is shortened, as these often relatively small series are re quired to provide solutions to more and more complex wishes with adaptations for special applications.
Production processes are crucial to quality 60 to 70% of the production costs in the hot rolling plant are accounted for by the
raw material. Added to this are the compli cated rolling, descaling and milling proces ses. Mast rail profiles must be quick and easy to process – any problems during ro botic welding at the customer’s factory are immediately referred back to the profile supplier. “Therefore, chamber dimension, radii, angles and surface finish play a very important role,” Mensinger explains “the (profile) production procedures have signi ficant influence on later processing ability. Since the lift truck manufacturers produce their masts at robotic welding stations, ra dii and tolerances play a much larger role than in manual welding, in which the wor ker can recognize tolerances and can inde pendently compensate for them. robots can only do this within a very limited range and thus the larger the tolerances, the slo wer they work and the more expensive each single mast becomes.” HSP’s custo mers already process profiles on their ro botic welding systems, which are designed for VNAtrucks, some with accompanying cabin and lifting heights of 17m and more. Another topic is the introduction three years ago of induction hardened leg channels for reach trucks. These Ushaped rails carry the mast and its loads horizontally for the life time of the reach truck. When delivered by HSP these Uprofiles do not show any wear during their lifetime. The leg channel pro file must not widen, wear or twist during operations, otherwise resistance to move ment increases with a consequent leap in energy consumption – always a critical fac tor for warehouse equipment.
SE-|M|® profiles
Complete offer In cooperation with the Italian roller be aring manufacturers, LiBe, HSP can now recommend roller bearings to fit all HSP profile sizes. Geometry, construction, be aring geometry and mounting are pre cisely matched to the data of the HSP mast rail profiles. This “package” of mast profiles and bearing shall be pre sented to selected customers from mid 2013.
SE|M|® (SEM = SPECIALLY ENGINEE RED MILLED) are hotrolled and sub sequently milled high performance profiles. The phenomenon of surface decarburization occurring during steel profile production has a significant ef fect on surface hardness and thus on the wear resistance of the profiles. By means of a predetermined addition of material, which is then removed by milling, the SE|M|® profile is an end product with no decarburized surface layer in the functional areas. Even after 100,000 load cycles, no significant wear was measured. The SE|M|® pro file is extensively protected in Europe and in the U.S. by patents.
CV: Jürgen Mensinger Mensinger was born in 1962. After at tending high school he trained at Hoesch Hohenlimburg AG. After qualifying for advance technical college he studied production engineering and returned to his employer after graduating. In 1992 he became Superintendent of the fi nishing department in the hot rolling plant. 2001 he moved to ThyssenKrupp VDM GmbH as Head of the Strip Division. His next career step was the move to the Schoeller Werke in Hellenthal/Eifel (a producer of stainless steel tubes) in Janu ary 2006 as Head of Technology and la ter as a member of the Board. On 01. June 2012, he became Technical Director and COO back at his old stamping ground in Schwerte. Jürgen Mensinger is married, is actively engaged in sailing and golf as well as passively with ice ho ckey. Taking care of a classic VW Beetle also takes up part of his leisure time.
Pictures: HSP Jürgen Mensinger has been technical Managing Director and COO of Hoesch Schwerter Profile GmbH since June 2012.
Warehouse Equipment
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STAPLERWORLD EUROPE 01-2013
Pallets automatically detected and localized The technology is based on the fusi on of the data of a laser scanner and a camera. The pallet sensor may be used in a variety of applications such as pallet transportation in con nection with a forklift or a rider-con trolled truck. The sensor is suitable for the operator controlled usage as well as for automated mode. Before the pallet is lifted any position of the pallet in front of the vehicle may be shown to the operator – similar to the supporting parking system for cars. The screen visualizes the opti mized access directions to the pallet depending on definable parameters. The operator only needs to follow the given path. The risks of an inaccurate navigation and the damage of the pallet and its goods are reduced significantly, which further positively affects the in-plant security. The sensor can also be adapted to an automated guided vehicle (AGV). At the lifting position for pallets it fulfills the tasks of navigation. FusionSystems uses a sensor concept for the previous described solution, which combines two technologies. For the two-steps concept, initially the distance information of the laser scanner is used to generate hypotheses for the existence and the position of the pallets. On the basis of image data the hypotheses are valida ted. Therefore, the assumed position of the pallet is being transformed into the camera image with the help of camera calibration data. At the local image position the existence of the pallet based on the hypothesis assumption is verified. Both steps use a geometric model that represents the dimensions and the 3D-shape features of the pallets, which should be detected.
Laser Data Processing: The first step, the detection of the pallet with the laser data, is based on the precise comparison of the geometric model of the laser scan and the given model of the pallet. Two shape features are of main interest: the consistency of the upper deckboards of the pallet (identified by the continuous lines in the laser scan) or the multiple existences of stringers (single short pieces that form a regular pattern in the laser scan). The approach of interest depends on the height of the scan. Accordingly, the laser scan processing is based on line recognition or pattern match of the stringers positions.
Image Processing: In the second step, the 3D-model of the pallet serves for the generation of the feature vector that collects evaluable features of the pallet in the image, which are used to verify the hypothesis. Pictures: FusionSystems GmbH
info FusionSystems GmbH I Tel.: +49 371 5347730 I www.fusionsystems.de
Warehouse Equipment
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STAPLERWORLD EUROPE 01-2013
Prevent the Machine-Theft: Not as expensive as we thought! Smaller then a cigarette box – Track Unit from Denmark The visit of a large rental fleet owner brought the realization that access systems are not lon ger the measure of all things, but web-based tracking systems. Sys tem so that, barely as large as a cigarette box, can be mounted somewhere on the truck and or operated either with onboard power and additionally buffered with a battery / storage capaci tor. These systems have a GPS module and they are equipped with a special SIM card like a mobile phone that (leaving a pre determined range = geofencing for example) send a text mes sage warning on certain settable events. Two systems fall upon us, there are Trackunit from Denmark and LostNFound from Switzerland - the charm lies in the ease of installation and use, and in the quite reasonable price - a benefit that would result from the liability insurance of machines in post reductions of 20 and more can affect percent. Trackunit was developed in Denmark in 2003 at the instigation of Volvo Cons truction Equipment. Hardware and software come from Den mark, there is also an app for smartphones, Worldwide, about 60,000 systems are in use, of which 30 % of forklift trucks, says Markus Grzbielok from the German distributor Beeware in Goslar. LostNFound is based in Zurich and produces its appliances in Taiwan. The company states that it has sold up to now systems to as many as 50,000 customers worldwide. There is a new ap plication for boats, of course, the same applies to truck. Engines can stop automatically when leaving a predetermined zone. For boats, a 399,- Euro solution will be available. The engine shutoff-function is not suitable for lift trucks because it must be possible for the users of a possible hazardous situation automa tically eject. This would not be possible for remote shutdown of the engine. Here, too, a SIM card from a status SMS, currently are 75 network providers signed agreements covering 145 coun
tries. This provider has with the Altus also a CanBus-capable version of the program that read and transmit a variety of motor and con sumption data can - a solution that can make problems with full service lease equipment, because the supplying OEM manufacturers its approval for “ must be tapped into ‘the bus, which is denied in many cases. (Oba) Anbieter
Trackunit
LostnFound
Produkt
ME301 / ME401
ALTUS
Hardwareprice
starting at 249,-
starting at 140,-
Isolation Class
IP67
IP65
Antennas integrated
yes
no
Integrated Battery
yes
yes
Size in mm
L75 x B45 x H18
L95xB110xH30
Cable Lenght
270
120 110
Weigt (gram)
60
Temperature Range
30 to 60° C
30 to 80° C
Voltage
12V, 24V und 48V DC
12V, 24V und 48V DC
Voltage Max
9 to 65
8 to 30
Inputs/outputs
4 digital, 1 digital
5 digital, 1 digital
Special Adaption for Lift trucks
yes
no
Präzise Signale
yes
yes
ManagerTool for Rental Companies
yes
no
Mobile-App
yes
yes
Live-Tracking
ja / variabel
yes
Fahrspuraufzeichnung/Historie
yes
yes
km-Meter
yes
yes
Geozonen-/Punkt-/Bewegungs-Alarm
yes/yes/yes
yes/yes/yes
Alarm for low Battery
yes
yes
Alarm Failure Battery Truck
yes
yes
Alarm missingh GPS-Signal
yes
yes
Info with SMS
yes
yes
Info with Email
yes
yes
Info on Web-Portal
yes
yes
Automatic Report Function
ja / ja
ja / nein
PDF/Excel-Export
yes
yes
Drivers Log
yes
yes
Built-In Battery
yes
yes
Driver Identification
yes
yes
Saving Date Periode
3
3
Hardware Alarm
Maps based on
GoogleM
GoogleM
Kartenmaterial Weltweit
yes
yes
Integrierte Antenne GPS / GSM
yes
yes
Kosten
Such is the small green box from Taiwan from the Swiss manufacturer.
Anschlussgebühren pro Box
no
no
Mindestlaufzeit Monate
12
24
Monthly Fee (Euro)
12,50 €
29,90 €
jährliche Kosten einmalig zusätzl.
no
no
Change of Userdata
no
no
Systemsperre
no
no
Tarifwechsel
no
no
Hardware made in Europe
Denmark
Taiwan
Anzahl aktivierte Hardware weltweit Stück
60000
50000
Ccomparison of the two systems. info Beeware GmbH: Tel: +49-5232-1749400 LOSTnFOUND: +41-44-5004095
Innovation push in Dornach: New ex-vehicles and Li ON technology are coming
The well known Swiss warehouse equipment manufacturer Stöcklin produces yearly about 1,400 units, by the majority standard devices like highlevel elevating platform truck and low elevating platform truck, double floor loader and special high/low pallet trucks are the main products. However, the special construction takes for many years a role be coming greater and greater. Business division leader Bruno Haller leads back this on the high flexibility of the proven assembly manufacturing and the very big manufacturing depth. Besides, important pivot leg is own hand elevating platform truck production – whose noble products are used particularly on LKW’s and with ground conveyors (endless chain conveyors in distribution centres). Main focus are and remain, however, walking devices and seat devices for the hard logistics application. For the important chemical industry based in Basel STöcklin manufactures for more than 30 years explosionproof warehouse trucks of all kind. Primarily these trucks have been built for zone ATEX 2 (formerly swath protection). Devices for the higher classified zone 1 were realised up to now with extruckconversion partners. In view of forthcoming adaptations of the ATEXnorms the business policy has radically changed – now Stöcklin is even one of very few European OEM manufacturers. To begin with one concentrates upon a new class EX from shaftlow elevating platform truck and high elevating platform truck whose base components are used like control, masts, load bearers and bicycle arms already in other classes. The new pedestrian stacker for zone 1 EXI 16 (1.600 kg) is certified for II 2G Ex de IIB + H2 T4 Gb“ and „II D Ex tb IIIB T 100° C Db”. This means that these devices can be used without conversion with gas and dust. Partner for the extensive certification and consul tation in the explosion protection is Atex an engineering in Dortmund. This service provi der offers the support to the acquisition of conformance certificates / certification by di rective ATEX (94 / 9 / the EC), and the directives BG3. In the meantime the enterprise became by the OFFICE VERITAS for manufacturing ATEX auditiert. info www.stoecklin.com
Pictures: STW
Special Lift Trucks
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STAPLERWORLD EUROPE 01-2013
Pioneering cutting edge technology For years, battery charging systems manu factured by Fronius have been enjoying growing popularity. The “Active Inverter Technology”, which is based on high fre quency technology, enables significant sa vings to be made in terms of electricity costs. In addition, battery maintenance requirements are reduced, battery service life is longer, valuable storage space is freed up and the significant reduction in CO2 emissions helps to protect the environment. All in all, the Total Cost of Ownership (TCO) is dramatically reduced. The charging tech nology is an advance on conventional in verter (HF) technology and is far superior to the old 50 Hz transformer technology. Fronius uses “Selectiva” battery charging systems for its intralogistics portfolio. They are characterised by a highly efficient use of energy, a constant power level throug hout the entire charging process, compact design and high safety standards. “Selec tiva” chargers have previously been available in three categories: “Selectiva”, “Selectiva Plus E” (E = single-phase) and “Selective Plus D” (D = three-phase). The first products of the new “Selectiva” generation are now available. Fronius has completely overhauled the three-phase de vices designed for the 24, 48 and 80 V traction batteries commonly found in elec tric forklift trucks, narrow-aisle trucks and electric tow tractors. There are three crite
ria in particular that make the new product range so exceptional: I Maximum energy efficiency I Maximum battery service life I Maximum safety “Selectiva Plus D” (7 and 14 kW) chargers are based on the proven “Active Inverter Technology”. What is new, however, is the innovative Ri charging process. What does this mean? What all battery charging tech nologies have in common – whether 50 Hz transformer technology, HF technology or earlier Fronius products that used “Active Inverter Technology” – is that their char ging processes use preprepared charging characteristics that are “imposed”, as it were, on the battery. This involves execu ting a defined charging program without having to take account of the current char ge level of the battery. Fronius chargers only take the charge level of the battery into account during the recharging phase. This ensures that any overcharging of the battery is kept to an absolute minimum. In this respect, the Austrian experts certainly set themselves apart from their competi tors. Fronius has opted for a completely new technical approach with its innovative Ri charging process. Once the charging plug is connected to the battery, the current charge level of the battery is permanently measured. This means that, regardless of
The new generation of “Selectiva” battery charging systems with the innovative Ri characteristic sets new standards in terms of energy efficiency and battery service life.
how old of new the battery is, its tempera ture and discharge level are monitored. The charger software uses this information from the battery to adjust the individual charging phases as required. This in effect means that each charging cycle is unique with its own individual characteristic. The new generation of “Selectiva” devices with “Active Inverter Technology” and the new Ri charging process have many bene fits for the user. Energy efficiency, for one. The efficiency of the battery charging sys tems is 93%. Charging efficiency, as well as process efficiency from the socket to ground conveyor, each increase by up to 10%. This must always be seen in compa rison with the values from the previous “Selectiva Plus D” series. In concrete terms, this means that during the conversion of AC from the socket to DC (required for battery charging) in the battery charger, and then during the subsequent electro chemical process during charging, energy usage is optimised to produce significant reductions in energy costs. Fronius is thus setting a new standard for energy effici ency. Evolution: Many product enhancements compared with predecessor devices build on the outstanding features of the “Selectiva” series
can now be replaced on site. When defective components are replaced on site, all relevant data remains s t o r e d in the device. The new devices have a modern USB interface for sys tem monitoring. These enable large amounts of recorded da ta to be exported and software updates to be installed more easily.
In addition to the lower energy consumption between the socket and the ground conveyor, the Ri characteristic has the added advantage of less battery warming during the charging process (and thus longer battery service life) and less water consumption due to the lower level of battery warming. In terms of battery service life, the Ri charging pro cess has another plus point: when the bat tery is only partly discharged, as is often the case, charging can be stretched out over the usual charging time – for example, seven hours. So the lower energy supply and the resultant lower warming levels, mean the battery can be charged very gently, avoiding peak currents.
much larger information display, which allows menus to be navigated more easily and more information to be dis played, also improves the userfriendliness of the device. New LEDs make it easier to read the status of the device from further away and thought has also been given to how service can be improved. As a result, individual components in the new devices
Photos: Fronius International GmbH info Fronius International GmbH Tel +43 664 602416436 www.fronius.com Copies: Boris Ringwald Froniusplatz 1 4600 Wels, Austria
A detailed look at the many advantages In addition to the new Ri charging process, the new devices boast many other enhan cements compared with their predeces sors, adding to the outstanding features already present in the former “Selectiva” range. Maximum output power has been increased from 7 to 8 kW and 14 to 16 kW respectively, increasing the maximum char ging current. The largest variant (80 V with 180 A) now weighs only 30 instead of 40 kg and is smaller in size. The ventilation con cept has also been reworked. This reduces the level of dirt in the battery charger, in creasing the service life of the charger even further. The new devices can also be up graded from the standard IP21 protection class to IP23. The new product generation even enables most available options to be integrated at a later date. The focus for the Fronius developers was to improve safety, userfriendliness, service and system monitoring. To improve safety, explanatory texts and a service callout telephone number will now appear along side the existing State code whenever the charger displays an error message. Mains voltage monitoring, safety cutout, deener gised charging plugs, reverse polarity pro tection, external startstop, timedelayed end of charging and a collective fault dis play round off the new safety features. A
TENSOR Leistung, die sich rechnet
»Die neue Hochleistungsbatterie für höchste Leistungsansprüche und maximale Wirtschaftlichkeit«
www.gnb.com GNB TENSOR Anzeige 140x194.indd 1
28.11.11 11:02
Special Lift Trucks
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STAPLERWORLD EUROPE 01-2013
Rough Times for Rough-Terrain Forklifts? The rough terrain forklift market is chan ging. In April 2013, the Spanish manu facturer Mecano Continental SA ceased production due to severe financial losses. Mast-products are no longer being built, although the range did reach at their end capacities up to 7000 kg. So the Mast-explorer (full Name of Mecanos range) seems to be history - it is of course possible that another manu facturer assumes any part of the production or the know how. Agria from Spain, actually best known for small lands caping machines, feature new all terrain forklifts with 4x4-drivetrain. The range fea tures payloads up to 3,000 kg, larger ma chines are supposedly being planned. Manitou is the clear market leader for all terrain forklifts, but has recognized that the large market for these devices lies in the U.S., so they have moved production
The Spanish supplier Mast is insolvent and no longer produces the Mast forklifts.
Manitou still has offroad-lift trucks with large front tires and front wheel drive in his program.
to Waco/ Texas, but the devices are built in the United States continue to be available at all retailers. JCB has also some models in the program and the STAPLERWORLD-reader who wants something individually crafted from Austria has to ask Bulmor for a Ran ger (4,000 to 6.000 kg).
4-Wheel drive and compact size characterize the handcrafted Ranger forklift from Bulmor.
info www.manitou.com www.bulmor.com www.agria.net www.jcb.com
Ausa presented at the Bauma2013 new Agrimatic-terrain forklift TH-175C to 1700 kg load capacity.
Votex Bison Material Handling BV De Geestakkers 6, 5591 RC Heeze T. +31 (0)40 - 226 32 19
www.votex-bison.com
VNA-Truck becomes AGV With the introduction of the Roboziner Dual Drive+ , Crepa and Frog will compete with existing solutions by offering a com bined manual and automatic application of VNA-trucks. The plus in the name says it all, according to the creators: this truck has more than previously was possible. Van der Helm-Hudig has implemented the first two Roboziners at its plant in Moerdijk. In recent years, various internal transport truck suppliers introduced various variants that can perform both manually and auto matically, the so-called dual-drive principle. With the Roboziner Dual Drive+, Crepa and Frog offer a solution that meets a gro wing need in the market. Companies that with a dual-drive truck, but ran into com plications had sometimes approached us in the past with the question if we could do something for them. Frog started 1986 with a new navigation concept that was based on a geometric grid of reference points in the floor with the help of cameras. Later, the navigation concept evolved and used transponders, magnets and lasers. The basis of the Robo ziner Dual Drive+ is the combi-truck of Ma gaziner, a German manufacturer. The truck is custom built. Standardly, the manufactu rer may supply trucks with a lifting height of 17 meters and a minimum residual ca pacity of 500 kg. Additionally, the unique mast design offers many practical advanta ges. Due to the fact that Magaziner builds its mast from traverses, it offers high rigidi ty while its own weight remains relatively low. With that low weight, it results in ra pid acceleration, high lifting speeds and
low power consumption. Compared to trucks that are equipped with a conventio nal mast, there is approximately 20% lower energy consumption. The Roboziner Dual Drive+ literally is two machines in one truck. With a physical key, the switch can be made between 100% manual hand drive and 100% AGV com mitment. Especially for a combi-truck de ployment, the ‘eyes’ are essential. For a secure and seamless deployment, it is im portant that the truck sees where the pal let openings are and whether a pallet can be placed on the assigned location. For recognition of for instance, pallets and lo cations, the Roboziner has a 3D camera placed on its forks. When picking up or putting away a pallet, the camera recogni zes the middle block of the pallet and then
the forks are automatically placed into the right position. This solution can also be applied to the handling of multiple pallet sizes. While driving, the dynamic contour scan is performed by sensors aboard the truck. Sensors on both sides of the Robozi ner continuously scan with a 2D field the contours of the pallet on the fork. If a pallet is not positioned correctly or if there is ano ther obstruction, the combi-truck will im mediately stop. Picture: Magaziner/Frog info Frog AGV Systems B.V. 3534 AP Utrecht/NL Fon: +31 (0)30 2728007 www.frog.nl QUALITÄT | ERFAHRUNG | ZUKUNFTSWEISENDE TECHNIK | INNOVATIONEN | NACHHALTIGKEIT | FLEXIBILITÄT | | ANBAUGERÄTE FÜR GABELSTAPLER | KREATIVITÄT | PREMI-
Anbaugeräte für Gabelstapler Container Spreader für Krane | Stationäre Handling Geräte
UM QUALITÄT | ERFAHRUNG | ZUKUNFTSWEISENDE TECHNIK | INNOVATIONEN | NACHHALTIGKEIT | FLEXIBILITÄT | INDIVIDUALITÄT | KUNDENSPEZIFISCHE LÖSUNGEN | ZUVERLÄSSIGKEIT | LANGLEBIGKEIT | PREMIUM SERVICE | ANBAUGERÄTE FÜR GABELSTAPLER | KREATIVITÄT | PREMIUM QUALITÄT | ERFAHRUNG | ZUKUNFTSWEISENDE TECHNIK | INNOVATIONEN | NACHHALTIGKEIT | FLEXIBILITÄT | INDIVIDUALITÄT | KUNDENSPEZIFISCHE LÖSUNGEN | ZUVERLÄSSIGKEIT | LANGLEBIGKEIT | PREMIUM SERVICE | ANBAUGERÄTE FÜR GABELSTAPLER | KREATIVITÄT | PREMIUM QUALITÄT | ERFAHRUNG | ZUKUNFTSWEISENDE TECHNIK | INNOVATIONEN | NACHHALTIGKEIT | FLEXIBILITÄT | INDIVIDUALITÄT | KUNDENSPEZIFISCHE LÖSUNGEN | ZUVERLÄSSIGKEIT | LANGLEBIGKEIT | PREMIUM SERVICE | ANBAUGERÄTE FÜR GABELSTAPLER | KREATIVITÄT | PREMIUM QUALITÄT | ERFAHRUNG | ZUKUNFTSWEISENDE TECHNIK | INNOVATIONEN | NACHHALTIGKEIT | FLEXIBILITÄT | INDIVIDUALITÄT | KUNDENSPEZIFISCHE LÖSUNGEN | ZUVERLÄSSIGKEIT | LANGLEBIGKEIT | PREMIUM SERVICE |
Die Hände Ihres Staplers
ANBAUGERÄTE FÜR GABELSTAPLER | KREATIVITÄT | PREMI-
KAUP GmbH & Co. KG
UM 865 QUALITÄT | ZUKUNFTSWEISENDE | Braunstraße 17 | 63741 Aschaffenburg | Telefon +49 6021 865 0 | Fax +49 6021 213 || ERFAHRUNG kaup@kaup.de | www.kaup.deTECHNIK | INNOVATIONEN | NACHHALTIGKEIT | FLEXIBILITÄT | INDIVIDU-
ALITÄT | KUNDENSPEZIFISCHE LÖSUNGEN | ZUVERLÄSSIG-
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KEIT | LANGLEBIGKEIT | PREMIUM SERVICE | ANBAUGERÄTE 02.01.2013 10:05:19
FÜR GABELSTAPLER | KREATIVITÄT | PREMIUM QUALITÄT | ERFAHRUNG | ZUKUNFTSWEISENDE TECHNIK | INNOVATI-
TR626i/TR632i: The Industry’s most powerful Heavy Terminal Tractors
STAPLERWORLD EUROPE 012013
Special Lift Trucks
36 37
Cargotec has introduced the new Kalmar TR626i and TR632i fully CANBus cont rolled heavy terminal tractors – which be come the most powerful models available in the industry. Targeting heavyduty indus trial and terminal applications, the new models meet the market’s current and pro spective demands for a higherpowered tractor that can handle the increasingly heavy loads seen in modern industries. Cargotec is the largest heavy terminal trac tor supplier in the world and boasts 20 years’ experience in heavy industrial tractor operations. Developed in response to cus tomer feedback, the new models extend the proven technology and systems from across the Kalmar tractor range to provide an agile, flexible and cost efficient heavy duty handling solution.
Key features include: I Industry leading capacities I Compliance with emissions legislation I Enhanced safety and operator environ ment I Easy maintenance and reduced owner ship costs
Performance and productivity The enhanced design of the new models ensures unrivalled performance in typical applications such as pulling heavy trailers up steep ramps onto RoRo ships, pulling long trains of trailers, or as a high perfor mance materials handling solution at hea vy industrial facilities such as, steel and paper mills. Uptime is one of the most crucial factors in these process industries and so reliability is at the forefront of the design of the new
models. Over 3000 hours were invested in the strength and reliability analysis of the main systems and components. The heavy duty frame and chassis have been purpose built for the demanding applications typi cal in port or industrial operations. Further more, the standard 300 litre fuel tank and 50 litre urea tank also ensure extended running time without refueling – delivering added productivity and uptime.
Unrivalled power and reliability Building on proven experience of delive ring high quality equipment for heavy in dustry, the new Kalmar terminal tractors are the highest capacity models that the company has ever manufactured and are more powerful than any other product on the market. They are powered by EU Stage IIIB and EPA Tier 4i emissionscompliant Volvo TAD1360VE series engines which in corporate the Volvo inline six concept. The TR626i and TR632i also feature a unique heavyduty active tilting lift boom which allows +/10° lateral inclination of the fifth wheel. This is more durable, stable and powerful than its predecessors. The inclination is adjusted by two double ac ting lift cylinders and can be easily cont rolled from the cabin. This allows the lift boom and fifth wheel to follow the terrain without torsion forces to the chassis, thus providing better balanced traction between all tyres. The feature also ensures safe ope ration and gives longer lifetime for the lif ting equipment components. The results are impressive lift capacities of 36 tons for the TR626i and 50 tons on the TR632i mo del. They also boast maximum GCW of 240 tons and 320 tons respectively.
Sensitivity to environment However, this increased capacity is not at the expense of environ mental performance. The Volvo engines use Selective Catalytic Re duction (SCR) technology to deliver near-zero NOx and harmful particulate emissions. They significantly reduce emissions without affecting capacity – meeting all legal obligations without sacrificing the level of productivity, safety and quality that Cargotec customers have come to expect. Furthermore, there is no increase in service intervals or costly downtime as the system is designed to last the lifetime of the engine.
Improved safety and operator experience Another key feature is the integration of a spacious new, air-suspen ded cabin which is electrically tilt-able to 60 degrees. The cabin is designed in accordance with ROPS safety standard (ISO 3471:1994). Wide footsteps, clear walkways, anti-slip materials and handrails further contribute to safety levels, making it easy to enter and exit the new tractors and allow safe and effortless access to trailer con nections. Cargotec has developed all of these features to enhance the precision and safety of terminal operations.Inside, the ergonomic design ensures a comfortable and productive operator environment. The controls are placed logically with revised easy-to-understand symbols. The height of the driving position provides excellent visibility in all directions while asymmetrical seating arrangement gives the driver a better view from the side window.
Great value for money with easy maintenance Full CAN-Bus interface technology allows more effective machine diagnostics and makes customisation easier. It also improves service ability, saves time and energy, enhances performance and reduces costs. The new 3.5” colour display shows all the necessary informa tion for a clear overview and superior control of the tractor. Clear and logical design has been applied across the entire layout of the Kalmar TR626i and TR632i models. The engine, air filter, pneu matic and hydraulic valves, hydraulic tank and CAN modules are within easy reach, as are the air tanks, batteries, urea control and tank and the diesel fuel tank.
WIR BAUEN STAPLER MIT HERZ
Stefan (links) und Lars-Göran sind Stapler-Monteure aus Leidenschaft. Sie arbeiten seit zehn Jahren als Team und bauen die leistungsstärksten und langlebigsten Stapler der Welt: Konecranes Gabelstapler, Reach Stackers und Containerstapler. Sie kennen jedes Detail und haben ein gemeinsames Erfolgsrezept: Wir bauen Stapler mit Herz. Machen Sie den Test – und spüren Sie den Unterschied. Konecranes GmbH (Lift Trucks) Wilhelm-Herbst-Str. 10, 28359 Bremen Tel +49 421 626706-0, Fax +49 421 626706-66 www.konecranes.de
Picture: Cargotec info Cargotec Tel. + 44 169 162 3100 I www.cargotec.com Anz. Lift Trucks 87x245_120412.indd 1
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Special Lift Trucks
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STAPLERWORLD EUROPE 01-2013
Robust 4-Way Trucks for Bright Steel Handling J. Adolf Bäuerle GmbH, based in Böblingen in the South of Germany, is part of the Georgsmarienhütte Holding group and is a leading manufacturer of bright steel pro ducts. It supplies various industries throug hout Europe such as the engineering, ag riculture, automotive and textile sectors with steel in a variety of specifications and finishes. Two 4-way Combilift forklifts have been brought in to handle the company’s material from the raw stage through to the finished product. The transport and storage of heavy and extremely long loads at Bäuerle used to be handled by a combination of sideloaders and overhead crane. “This process left a lot to be desired,” says Plant Manager Micha el Keppeler. “The limited manoeuvrability of the sideloader increased the risk of da mage to the product, and double handling slowed down the entire handling process.”
the relatively narrow entrance door is easy to negotiate and loads can be deposited at the precise spot where they are required. “These are the first trucks we have had that are capable of doing this,” says Michael Keppeler.
Two Combilift C6000 diesel powered 6t capacity models have now replaced the previous system for much more efficient handling of steel inside the factory buil ding itself and in the separate warehouse. The trucks ensure easy transportation of the bundled steel, which ranges from 3 to 9 metres in length, from storage areas to the production line. Thanks to the Combilifts’ ability to travel side ways with long loads,
Thanks to their robust design, the Combi lifts can easily cope with the harsh condi tions at Bäuerle, operating two-shifts from 5.30 am to 11 pm. The generous capacity of the C6000 model enables two bundles to be carried simultaneously, thereby con siderably enhancing production throughput. Low level trans portation of loads resting on the integrated platform also improves safety procedures. “The spacious cab and the te lescopic forks are perfect for efficient operation and for driver comfort,” explains Mi
chael Keppeler. “Because of the long hours that the operators spend driving around inside and outside the building, it is essential that we provide them with a comfortable environment. The telescopic forks facili tate the loading and un loading of trucks, and the agility of the vehicle makes it ideal for manoeuvring in the tight spaces between pro duction areas. With these highly flexible trucks, we are able to store our materials more efficiently and thereby increase pro ductivity.” Combilift 4-way forklifts are all designed and built in Monaghan, Ireland, where the company has its HQ and R&D facility. The current Combilift range now encompasses at least fifteen base models with capacities ranging from 2.5 – 25 tonnes, with LPG, diesel or AC electric power available. Com bilift has won numerous awards for its products since the company was establis hed in 1998, and there are now around 18,000 units in operation around the world. Pictures: Combilift info Combilift Ltd., Co. Monaghan, Ireland Tel: 00353 47 80500 Germany: 0800 000 5764 www.combilift.com
Innovative Household Appliance Clamps The forklift attachment manufacturer Dur wen, based in Plaidt near Koblenz, has be en known for many years for its innovative and service-optimised products for the drinks and logistics industries.
tented valve and hydraulics technology has significantly reduced the lost load cen tre, thereby increasing the lift truck’s load capacity.
Recently we have made it our mission to transfer this knowledge to the carton / household appliance clamps industry as well. All clamps benefit from the Durwen Service Plus technology (DSP), which has the fundamental characteristic that many of the components are bolted together. This results in significant on-going operati onal cost savings as worn parts can be re placed individually. For example, the arms are bolted onto the rest of the structure and not welded. It is particularly important to select the right attachment due to the differing nature of the goods and their applications. As well as the weights that need to be lifted you need to choose bet ween clamps with fixed, single oscillating or dual oscillating arms. In addition there are different opening ranges for the trans port of 2, 3 or 4 appliances next to one another, as well as 1 or 2 appliances in front of or on top of one another. Durwen has also put some thought into the type of coating on the arms as well as adjust ments to the arms’ geometry, in order to achieve an optimum distribution of force on the cargo. The technical data is not to be ignored. This has a significant effect on the lift truck’s load capacity. Special pa
Durwen is of the opinion that this product, with its good visibility offering high levels of safety for the lift truck driver, is an excellent addition to the market. Many customers in the white goods, fruit and vegetable transport and logistics industries are already using these types of clamps from Durwen. Picture: Durwen info Durwen Maschinenbau GmbH 56637 Plaidt Tel. + 49 (0) 2632-7000-0 www.durwen.de
Wir warten auf Sie auf der LOGIMAT, Halle 9 / Stand 542 !
In Europa ereignen sich innerhalb eines Jahres 200.000 Unfälle auf Leitern
Durch BRAVI-Arbeitsbühnen Könnte diese Zahl erheblich reduziert werden.
A92.6
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Accesoires
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STAPLERWORLD EUROPE 01-2013
Hyster lifetime costs attract Katoen Natie Katoen Natie has purchased nine Hyster ReachStackers, one 25 and one 32 tonne forklift truck following a challenging ten der process designed to identify the best total cost of ownership. The new units are used to handle shipping containers of all sizes in high intensity terminal and steve doring applications around Antwerp, Bel gium. After the first months of operation Katoen Natie measured a 6 l/h (litre per hour) saving per truck. Over a 5 to 6 year period this could amount to 90,000 litres saved. At the beginning of 2011, a tendering pro cess started. Several equipment suppliers were involved in the highly critical and cal culated decision making process designed by the global logistics service provider. Dirk Waeterschoot from Katoen Natie explains “We were looking for total cost of owner ship figures to understand the full scope of our investment for the life of the new equipment.” Katoen Natie calculated each individual detail that affects the lifetime cost of the equipment and overall uptime. Following a challenging specification process, which included every single element in the calcu lations including maintenance rates and resale value, the contract was finally awar ded to Barloworld Handling, the Hyster distribution partner in Belgium. One of the key elements looked at was the fuel consumption and the way in which the different brands achieve Tier 4i/Stage IIIB emissions compliance. Dirk Waeterschoot reports “Hyster has done an excellent job together with Cummins to not only achie ve a significant reduction in fuel consump tion, but eliminate the need for AdBlue and associated hidden costs and hassle”. All Big Trucks over 16 tonne lift capacity use Exhaust Gas Recirculation (EGR) technology, so the operators can fill the fuel tank as normal without having to use the urea re sin known as AdBlue, unlike other sup pliers. Hyster claims that fuel savings of up to 15% are now typical across its new big truck range but savings of up to 20% are achievable in reachstacker applications.
Katoen Natie is using the RS46-36 Reach Stacker which provides a capacity of 46 tonnes in the first row and 36 tonnes in the second, providing between 100 and 140 moves per shift. Another expense that Katoen Natie focused on was tyres. To help monitor and reduce the number of tyres used, the equipment is fitted with a tyre pressure monitoring system to ensure that the tyres are always fully inflated, helping to reduce wear and optimise performance. Additional features such as a fixed speed limiter, a camera and radar system to help prevent damage, LED lights, an auto-grea sing system to lower maintenance costs and an empty seat switch-off, also help to contribute to a low total cost of operation. To provide fleet intelligence, a fleet manage ment system by Barloworld also helps mo nitor the performance of the equipment and reports any major impacts. All drivers are highly experienced and trained on the Hyster trucks, but the system provides ad ditional accountability to further reduce damage. “This is a completely new gene ration of reachstacker,” explains Danny. “Not only did we audit the build quality, we involved the drivers in the decision ma king process, two of which joined us on our visit to the factory in Nijmegen, to test the trucks.” All the trucks feature the Hyster ‘Vista’ Ope rator Compartment which offers excellent comfort, outstanding ergonomics, all-round visibility and low noise levels. There is rapid boost at low engine rpm and high boost at higher rpm thanks to the Variable Geo metry Turbocharger (VGT™). The trucks also only provide maximum power on de mand, when it is really needed, with loadsensing hydraulics that ‘feel’ the load weight that is lifted. As maximum loads are not always handled, even less fuel is consumed.
After testing, Katoen Natie decided to achieve the maximum fuel saving by selec ting the ECO-eLo “fuel efficiency” mode, and features such as oil-immersed brakes, a robust drive-axle and powertrain protec tion help to maintain maximum producti vity and dependability. In support of the equipment, Barloworld Handling has resident engineers and work shop facilities on each site to ensure that routine maintenance is effectively carried out and to ensure fast response in the event of breakdown. “This contract is not only about the machi nes, it is about uptime and the best value handling solution so that we can provide superior levels of service to our Katoen Na tie customers,” adds Dirk. “This is a long term partnership as we seek to drive down cost, boost productivity and increase effici ency.” Katoen Natie is a global logistics service provider for several key industries, offering integrated logistics solutions such as warehousing and storage, packing and packa ging, transport and distribution, value-added services, cleaning and repair, projects and process engineering and port operations. The company was formed in 1854 and it employs over 9,000 people worldwide. Hyster warehouse, IC and big trucks are widely used at Katoen Natie locations ac ross the world. Picture: Hyster
info www.hyster-bigtrucks.com
Pallet Stacker in Standardand Special Customised design Rider seated high lift pallet trucks – the picture shows the typical operating situation; the floor must be free for the lift arm device; that means the lowest pallet has to be taken out before operating the upper trays. This can be avoided by lifting the first pallet tray, which however costs money (traverse) and requires storage space. Therefore, there are fast and manoeuvrable vehicles which are a lot cheaper than reach trucks. The Still FVX is offered in several versions for 1,200/1,600 mm load at 600 mm LSP. The triplex masts manage up to 5466 mm. 24 V and battery capacities of 440 to 640 Ah make it clear that the heavy duty performance has already been considered here. The turning radius amounts to 1,760 mm, the working aisle width of the approximately 1.6 t heavy vehicle which is ready for use is specified with 2,626 mm lengthways for pallets. The lifting and traction motors achieve 3 kW each. info www.still.de
Picture: Still
4-Way Handling www.combilift.com
• Space saving, safe and productive handling • Robust and versatile • Capacities from 2.5 – 25 tonnes • Diesel / LPG / AC Electric Without Combilift
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Combilift Ltd Gallinagh Co. Monaghan Ireland HQ Tel: +353 47 80500 UK: 07870 976 758 Germany: 0800 000 5764 E-mail: info@combilift.com
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Visit to BulmorSideloaders in Perg/Austria. ReachtruckUpdate – all new models and their features. Sany about to enter the European Market with Rechstackers and Lift Trucks. Seats for Comfort and Productivity – Latest Products from KAB, Sears, United Seats, Grammer, Isri, Savas and many more. Electro CBTrucks from 4 to 12 tonnes – the big ones are coming. Sainless SteelWarehouseEuqipment. Hinrichs Flurförderzeuge gives second Life to used ContainerHandling Equipment. Mora Compact CB´s from Italy – strong reputation in many branches. Double Pallet Handling – what makes a valuable truck? Terminals for heavy duty application in warehousing, cold storga enad outdoor use. Cabines of the Future: Many Manufacturers work on sophisticated Solutions. Terberg: Europe´s No 1 Terminal Tractor Manufacturer goes electric!
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Editorial Deadline: 26. August 2013 Advertisement Deadline: 09. September 2013 Issuing Date: 01. October 2013
“We both operate on higher standards”
The Hyundai 250D-7E forklift truck Power means nothing without control. That’s why the 250D-7E handles even the heaviest loads with refined precision. From its low centre of gravity to its load sensing system, its the star of its class in both safety and costeffectiveness. The competition can’t touch it, even when just on standard equipment. For more information, please find your nearest Hyundai dealer at www.hyundai.eu.
Moving you further HHIE UK | Unit 15 Bilton Industrial Estate | Lovelace Road | RG128YT Berkshire | +44 (0) 1344 484 034 | info.uk@hyundai.eu | www.hyundai.eu