Search Results (18)

End-of-life electric vehicle (EV) batteries can be reused to reduce their environmental impact and economic costs. However, the growth of the second-life market is limited by the lack of information on the characteristics and performance of these batteries. As the volume of end-of-life EVs may exceed the amount of batteries needed for stationary applications, investigating the possibility of repurposing them in mobile applications is also necessary. This article presents an experimental test that can be used to collect the data necessary to fill a battery passport. The proposed procedure can facilitate the decision-making process regarding the suitability of a battery for reuse at the end of its first life. Once the battery passport has been completed, the performance and characteristics of the battery are compared with the requirements of several mobile applications. Mobile charging stations and forklift trucks were identified as relevant applications for the reuse of high-capacity prismatic cells. Finally, a definition of the state of health (SoH) is proposed to track the suitability of the battery during use in the second-life application considering not only the energy but also the power and efficiency of the battery. This SoH shows that even taking into account accelerated ageing data, a repurposed battery can have an extended life of 11 years at 25 °C. It has also been shown that energy fade is the most limiting performance factor for the lifetime and that cell-to-cell variation should be tracked as it has been shown to have a significant impact on the battery life. Full article

Centimeter-level localization and precise rotation angle estimation for flatbed trucks pose significant challenges in unmanned forklift automated loading scenarios. To address this issue, the study proposed a method for high-precision positioning and rotation angle estimation of flatbed trucks using the BeiDou Navigation Satellite System (BDS) and vision technology. First, an unmanned forklift equipped with a Time-of-Flight (ToF) camera and a dual-antenna mobile receiver for BDS positioning collected depth images and localization data near the front and rear endpoints of the flatbed. The Deep Dual-Resolution Network-23-slim (DDRNet-23-slim) model was used to segment the flatbed from the depth image and extract the straight lines at the edges of the flatbed using the Hough transform. The algorithm then computed the set of intersection points of the lines. A neighborhood feature vector was designed to identify the endpoint of a flatbed from a set of intersection points using feature screening. Finally, the relative coordinates of the endpoints were converted to a customized forklift navigation coordinate system by BDS positioning. A rotation angle estimation was then performed using the endpoints at the front and rear. Experiments showed that the endpoint positioning error was less than 3 cm, and the rotation angle estimation error was less than 0.3°, which verified the validity and reliability of the method. Full article

In tandem with the advancement of urban intelligent technology, the construction of remote monitoring platforms and databases for non-road mobile machinery is gradually improving in various provinces and cities. Employing the remote monitoring platform for non-road mobile machinery enables a detailed big data analysis of the actual operational state of the machinery. This method yields precise data on the activity levels of various machinery types. Importantly, it addresses the issue of reduced accuracy in emission inventories, which often arises from the conventional practice of using standard recommended values from the Guide to determine machinery activity levels during the compilation of non-road mobile machinery emission inventories. Based on the remote monitoring and management system of non-road mobile machinery, the actual value of the activity level of non-road mobile machinery was obtained, and the emission inventory of non-road mobile machinery in Shandong Province was established. The emission levels of PM, HC, NOx, and CO from main non-road mobile machinery, including forklifts, excavators, loaders, off-road trucks, and road rollers, were measured. The findings indicate that the operational activity levels of non-road mobile machinery in Shandong Province typically exceeded the guideline’s recommended values. Among them, the annual use time of port terminal ground handling equipment was the longest, with an average annual working time of 4321.5 h per equipment, more than six times the recommended value. Among all types of non-road mobile machinery, loader emissions accounted for the highest proportion, reaching 43.13% of the total emissions of various pollutants. With the tightening of the national standard for non-road mobile machinery from Stage II to Stage III, a significant reduction in actual mechanical emissions was observed, primarily manifested as a 91% decrease in NOx emissions. Based on the data from the remote monitoring platform, a new method for compiling the emission inventory of non-road mobile machinery is proposed in this paper. The calculated emission inventory can reflect more real emission situations and provide a reference and basis for emission control and sustainable emission reduction policy measures for non-road mobile machinery. Full article

This study presents a theoretical framework for defining the performance level of wireless safety functions within industrial environments. While acknowledging the simplifications inherent in our approach—primarily based on packet loss rates as a measure of system performance—the study underscores the dynamic challenges posed by real-world warehouses. Through an in situ measurement study of a forklift truck safety system, we validate the proposed method and emphasize the need for a more nuanced examination of wireless communication in complex settings. The study advocates for an expanded theoretical framework that considers fluctuations in warehouse dynamics, accounting for their impact on packet loss rates and, consequently, the precision of performance-level assessments. Furthermore, the research highlights the complexity introduced by wireless system characteristics not addressed in the simplified model, urging future investigations to incorporate these factors for a comprehensive understanding of wireless safety systems. The absence of specific criteria for wireless systems within existing standards emphasizes the necessity for a specialized framework in addressing safety aspects unique to wireless applications. Full article

Similar to many complex systems, the operation process of electric balanced forklifts has characteristics such as time-varying model parameters and nonlinearity. Establishing an accurate mathematical model becomes challenging, making it difficult to apply model-based control methods in engineering practice. Aiming at the longitudinal control system of electric forklifts containing external disturbances, this paper proposes an improved full-format dynamic linearization model-free adaptive PID control (iFFDL-MFA-PID) method. Firstly, the full-format dynamic linearization (FFDL) method is employed to transform the operating system of the electric balanced forklift into a virtual equivalent linear data model. Secondly, the nonlinear residual term and pseudo-gradient (PG) of the data model are estimated using the difference estimation algorithm and the optimal criterion function, respectively. Furthermore, in order to enhance the robustness of the system, the idea of intelligent PID (iPID) is introduced and the principle of equivalent feedback is utilized to derive the iFFDL-MFA-PID control scheme. The design process of this scheme only requires the use of the input and output data of the system, without relying on the mathematical model of the system. Finally, the iFFDL-MFA-PID method proposed in this paper is simulated and tested with the EFG-BC/320 counterbalanced forklift equipped in the Special Equipment Testing Center and compared with the model-free adaptive control method (FFDL-MFAC) and the PID control method. Simulation results show that the speed-tracking error of the electric forklift truck under the action of the iFFDL-MFA-PID algorithm is maintained within ±0.132 m/s throughout the process, achieving higher tracking accuracy and better robustness compared to the MFAC and PID methods. Full article

Counterbalanced forklift trucks (FLT) are frequently used in combination with interchangeable equipment in order to handle loads in different manners. The main risks which may arise after assembling interchangeable equipment to a FLT are related to the loss of stability of the assembly. Actually, the presence of interchangeable equipment and the associated payload may change in a significant way the overall centre of gravity with respect to the FLT in its basic configuration with forks. Therefore, the stability limits of the assembly, based on the same footprints on the ground of the FLT alone, are affected by the position of the overall centre of gravity. Thus, the presence of interchangeable equipment could reduce the functionality (e.g., lifting capability, lifting height, etc.) of the FLT in order to continue its stability during use. Often, interchangeable equipment is placed on the market by manufacturers other than the FLT manufacturer. In these cases, the correct and safe coupling of the interchangeable equipment with the FLT is the responsibility of the manufacturers of interchangeable equipment, including the stability risk assessment. Thus, the interchangeable equipment manufacturer should have access to the relevant information of the FLT concerning operative and structural features and its configuration as a procedure for assessing the correct and safe coupling. Otherwise, he should perform experimental stability tests for each model of FLT so that its interchangeable equipment can be fitted. Specific research activity is developed in order to define an analytical procedure to assess the stability of FLT when assembled with interchangeable equipment. Specific typologies of FLTs and interchangeable equipment have been selected in order to better characterise the case study. The analytical equations mimic the static stability tests. The results achieved have been compared to experimental data in order to optimise the procedure. The results attained by the application of the analytical procedure to all the combinations of main typologies of FLTs and the interchangeable equipment selected showed good agreement with experimental tests. Full article

The in-factory transport influences production rate and quality, so it is characterized by the shortest displacement time and maximum utilization of available means of transport, accompanied by their lowest operating wear. In the paper, an improvement of factory transport management is suggested, employing the traffic analysis methods of industrial vehicles. The efficiency of internal logistics was analyzed with the use of the WiFi-based technique for monitoring industrial vehicles. In the research, the in-building location system Optimatik BI was used and implemented in a company manufacturing PVC profiles for the market of building materials and interior equipment. Stopping times of forklift trucks, their routes and covered distances were estimated. On this ground, factors of their effective use were calculated. Further, it was possible to analyze the traffic of the forklift trucks and to generate heat maps that, in turn, made it possible to identify problems and develop a suitable improvement plan. A mathematical model that allows for efficiency optimization by determining the best number of employees handling the transport was developed for one of the analyzed logistics tasks. Full article

Fuel cell electric vehicles (FCEV) are developing quickly from passenger vehicles to trucks or fork-lifts. Policymakers are supporting an ambitious strategy to deploy fuel cell electrical vehicles with infrastructure as hydrogen refueling stations (HRS) as the European Green deal for Europe. The hydrogen fuel quality according to international standard as ISO 14687 is critical to ensure the FCEV performance and that poor hydrogen quality may not cause FCEV loss of performance. However, the sampling system is only available for nozzle sampling at HRS. If a FCEV may show a lack of performance, there is currently no methodology to sample hydrogen fuel from a FCEV itself. It would support the investigation to determine if hydrogen fuel may have caused any performance loss. This article presents the first FCEV sampling system and its comparison with the hydrogen fuel sampling from the HRS nozzle (as requested by international standard ISO 14687). The results showed good agreement with the hydrogen fuel sample. The results demonstrate that the prototype developed provides representative samples from the FCEV and can be an alternative to determine hydrogen fuel quality. The prototype will require improvements and a larger sampling campaign. Full article

Pallet racking is a fundamental component within the manufacturing, storage, and distribution centers of companies around the World. It requires continuous inspection and maintenance to guarantee the protection of stock and the safety of personnel. At present, racking inspection is manually carried out by certified inspectors, leading to operational down-time, inspection costs and missed damage due to human error. As companies transition toward smart manufacturing, we present an autonomous racking inspection mechanism using a MobileNetV2-SSD architecture. We propose a solution that is affixed to the adjustable cage of a forklift truck, enabling adequate coverage of racking in the immediate vicinity. Our proposed approach leads to a classifier that is optimized for deployment onto edge devices, providing real-time alerts of damage to forklift drivers, with a mean average precision of 92.7%. Full article

Currently in Europe, road freight transport is characterized by the most dynamic advancement. Year after year, we may observe an increase in the amount of transported goods. The paper presents the emissions of gaseous exhaust components such as CO, THC, and NO_x as well as fuel consumption in freight transport. The emission analysis was performed for the entire transport cycle covering the handling of the goods with forklifts and carriage with a heavy-duty truck. The investigations were performed under actual conditions of operation using a Portable Emission Measurement System (PEMS). The fuel mileage was determined using the carbon balance method. The test routes were designed so as to reproduce the transport-logistic system typical of small towns. The setting for the tests was a town located in central Poland near the A2 motorway constituting part of the trans-European logistic network with multiple locations of logistic centers. In order to present the real emissions during handling, two test variants were considered: an outdoor variant (on a nearby lot) and inside a warehouse. The test run of the heavy-duty truck involved transporting 24,000 kg of load on urban and extra-urban (local and intercity) roads. The exhaust emissions and fuel mileage were determined for each of the stages as well as for the entire research cycle. Full article

Machine Activity Recognition (MAR) can be used to monitor manufacturing processes and find bottlenecks and potential for improvement in production. Several interesting results on MAR techniques have been produced in the last decade, but mostly on construction equipment. Forklift trucks, which are ubiquitous and highly important industrial machines, have been missing from the MAR research. This paper presents a data-driven method for forklift activity recognition that uses Controller Area Network (CAN) signals and semi-supervised learning (SSL). The SSL enables the utilization of large quantities of unlabeled operation data to build better classifiers; after a two-step post-processing, the recognition results achieve balanced accuracy of 88% for driving activities and 95% for load-handling activities on a hold-out data set. In terms of the Matthews correlation coefficient for five activity classes, the final score is 0.82, which is equal to the recognition results of two non-domain experts who use videos of the activities. A particular success is that context can be used to capture the transport of small weight loads that are not detected by the forklift’s built-in weight sensor. Full article

The lithium-ion battery (LIB) represents a useful lever for reducing material handling equipment’s (MHE) environmental impact. The exploitation of opportunity charging might improve LIB adoption, which is still prevented by the high investment cost. Since opportunity charging is affected by the system organization, the relationship between LIB and organizational variables is a meaningful work direction to reduce warehouses’ environmental impact, which is underrepresented by the current literature. The present paper aims at filling this gap by investigating the implications of organisational variables on LIB adoption in warehouses where handling activities are performed with forklift trucks. Based on an in-depth review of the literature and semi-structured interviews, the research presents an input-process-output model linking organisational variables and LIB forklift related costs with an application to a real case. This paper is original as it extends findings from the research fields of production and mobility to the warehouse arena, and it opens room for further research on warehouse sustainability. The paper also offers insights to warehouse managers making decisions about LIB adoption for their electric forklift fleets. This is particularly meaningful to reduce warehouse environmental impact, since MHE power source significantly contributes to greenhouse gases emissions. Full article

This study investigates the dynamic behavior of a recently developed counterbalance forklift truck. The final objective is creating virtual testing tools based on numerical multibody models to evaluate the dynamic stresses experienced by the forklift family of interest during a reference operating cycle, defined by the manufacturer’s testing protocols. This work aims at defining sufficiently accurate and easy-to-implement modelling approaches and validation procedures. It focuses on a specific test, namely the passage of a speed-bump-like obstacle at high velocity, which represents one of the most severe conditions within the reference cycle. Indeed, unlike most of the other wheeled vehicles, forklifts typically do not have advanced suspension systems and their dynamic response is significantly affected by ground irregularities. To this end, a preliminary model of the complete forklift, featuring rigid bodies and a simplified tire–ground contact model, is implemented with a commercial software. Experimental tests are conducted on the forklift to measure the vehicle vibrations when running on the obstacle, for model validation purposes. After model updating, the results provided by the numerical simulations match the experimental data satisfactorily. Hence, the modelling and validation strategies are proven viable and effective. Full article

Location and tracking needs are becoming more prominent in industrial environments nowadays. Process optimization, traceability or safety are some of the topics where a positioning system can operate to improve and increase the productivity of a factory or warehouse. Among the different options, solutions based on ultra-wideband (UWB) have emerged during recent years as a good choice to obtain highly accurate estimations in indoor scenarios. However, the typical harsh wireless channel conditions found inside industrial environments, together with interferences caused by workers and machinery, constitute a challenge for this kind of system. This paper describes a real industrial problem (location and tracking of forklift trucks) that requires precise internal positioning and presents a study on the feasibility of meeting this challenge using UWB technology. To this end, a simulator of this technology was created based on UWB measurements from a set of real sensors. This simulator was used together with a location algorithm and a physical model of the forklift to obtain estimations of position in different scenarios with different obstacles. Together with the simulated UWB sensor, an additional inertial sensor and optical sensor were modeled in order to test its effect on supporting the location based on UWB. All the software created for this work is published under an open-source license and is publicly available. Full article

Rail transport has unmistakable sustainable (environmental and economic) advantages in goods transportation on a massive scale. Goods loading constitutes an important segment of goods transportation by rail. Incorrect loading can be a serious threat to traffic safety as well as a generator of unforeseen expenses related to goods, railway infrastructure and vehicles. At the beginning, the paper identifies the presence of incorrect loading into freight railcars. The analysis of the available loading software has led to the conclusion that no software offers adequate support to the planning and monitoring of the loading of goods into a covered railcar using a forklift truck. For this reason, the main aim of the research is to formulate a mathematical model that includes real-world constraints, as well as the design and implementation of an original user-friendly load planning and monitoring software system. Experimental evaluations of the implemented software have been made based on single and multiple railcar pallet loading problems, considering the following three optimization criteria: maximization of wagon load weight, maximization of wagon volume utilization and maximization of weighted profit. By testing the optimization and visualization features of the software and analyzing the results, it has been concluded that it can offer full support to real load planning and monitoring problems. Full article