Raising the stakes
April 1st 2007

The company took a non-standard approach to standard requirements: improvements in ergonomics; enhanced energy efficiency and performance; increased safety features; reduced lifecycle costs. Flexibility was a prime consideration in all elements.

"Contracts are getting shorter so customers need flexibility," said Sebastian Riedmaier, head of product management, warehouse systems technology, at the EKX press launch at Jungheinrich's Moosberg plant. "Another major factor is ergonomics: the driver is a major cost so comfort and safety must reflect that. As the performance of the truck improves, so must the safety and comfort. The third driving factor was better energy management, to increase performance and energy efficiency by 20-30 per cent. All of which add up to reduced life cycle costs, which are much more important to the customer than the upfront cost of the truck." The result is a sophisticated, RFIDcontrollable, modular machine, capable of completing two shifts on a single charge, that can be programmed to accommodate individual needs. According to Jungheinrich, it is also the first truck in the market to acquire a TÜV Safety Integrated Level 2 (SIL), futureproofing the EKX in terms of new European legislation over the next few years.

Ergonomics & safety "The driver is very important and we need them on our side," says Riedmaier. "If we can achieve that, we win this game in most cases. So, in the electronically adjustable cab, we've created more space – beginning with the entrance which we've lowered 60mm. A small difference, but one which the driver will notice getting on and off the truck 20, 40, or 60 times a day. We've also increased headroom by 50mm and added more space for the shoulders, legs and feet.

We've created a new seat with a simple, singlemovement electronic sit/stand function and a knee rest for when the driver is leaning forward. The windows and windscreen are also larger, giving the driver a better view of the forks, and the windows are safety glass, not plastic, to improve visibility." Control: JungheinrichXP "On the mechanical side, there isn't that much difference between the major manufacturers," says Riedmaier. "The difference lies in the controls and we have taken a major step forward with our new control system: JungheinrichXP." The two channel operating system means all the information goes in parallel. "It's like an emergency parachute," he explains. "We have one master computer and one 'safe' computer: the CAN-Bus system is the first in the market granted the SIL2 certificate." So what possibilities are created? According to Jungheinrich, it improves the integration of the truck within the warehouse system: the ground; the racking; the material management system – the requirements of which can fluctuate according to demand.

Which is where RFID control control comes into its own.

The RFID transponders, plug-like capsules that are embedded into the warehouse floor using a standard drill and then covered with silicone, take the information from the floor to the truck as it travels – and control operations accordingly. So if the floor is rough in a particular aisle, the truck will go slowly for that section. If height is restricted, the lift height limited etc. "And because the truck is referencing every 10m or so, via the wheels and by the transponder, you know exactly where the truck is: which aisle at what speed restrictions and truck position to the millimetre," Riedmaier explains. "It's like GPS but from the floor. And if anything changes, just reprogram the chips." According to the company, the chips cost around €5, with similar installation cost. A 50m aisle with eight transponders would therefore only cost about €80 to implement.

Energy management Simultaneous operations, such as rapid acceleration and lift creates overlapping currents, which drain power. So Jungheinrich's active energy management system addresses the demands individually.

"It 'looks' at the current and decides to accelerate first. Half a second later, when the current demanded by acceleration decreases, it switches current to maximum lift speed, vastly improving battery life," states Riedmaier. "And when the battery gets low, it reduces the performance very slightly, around 10 per cent. The operator doesn't even notice and the battery life is extended." Regenerative lowering also enhances battery lifecycle.

The result is 30 per cent more efficiency, and customers can choose different performance kits to determine where the efficiencies are made. For example, standard trucks offer 10 per cent higher performance with 20 per cent less energy consumption.

But if the customer requires faster lift and driving speed, the ratio can be shifted to 20 per cent higher performance and throughput with 10 per cent less energy consumption.

"We have a performance kit for all applications," says Riedmaier.

The highly modular 1.5t truck, which is offered on 2,000 hour maintenance intervals, has a long list of other enhancements that give credance to the company's initial claim: that the EKX is an industrial milestone. For detailed technical information, either call the number below or go online.

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