Island to recharge your batteries

Whether LED illuminated advertising systems or WPC decking boards - products from Thyssenkrupp Plastics in Essen can be found in many areas. The company is part of Thyssenkrupp Materials Services and is a service provider for plastics operating throughout Germany with a total of 18 locations. In April 2022, the wholesaler opened a new logistics center in Tornesch near Hamburg. From there, the semi-finished product specialists supply customers in northern Germany.

Charging infrastructure for smooth material flow

In the logistics hall, seven electrically powered four-way forklifts from Jungheinrich ensure a continuous flow of materials in two-shift operation. The prerequisite: a reliable charging infrastructure. The plastics company relies on the Selectiva 4.0 chargers from Austrian manufacturer Fronius Perfect Charging. Together with Thyssenkrupp Plastics, the battery charging experts developed a free-standing stand-alone solution for greater flexibility and safety in intralogistics. The charging station is based on the Fronius Charging Module 2000, with a special height of 2,700 millimetres for the application in Tornesch. Adapted to the requirements in the hall, the power supply comes from above the charging modules via a cable bridge.

Everything accessible, but nothing in the way

The free-standing installation allows the user to safely charge the lead-acid batteries beyond the prescribed minimum distance. The Fronius system also offers another advantage: the first aid equipment is now clearly visible at strategic points in the halls and no longer far away on external walls or on storage shelves. "This means that everything is immediately accessible but not in the way," says Mario Götte, Deputy Operations Manager at thyssenkrupp Plastics. "And the stations simply look good. That plays a major role, also for our employees."

Individual characteristic curves of the batteries

In addition to safety and appearance, the stations impress with their core competence: Selectiva 4.0 chargers supply the forklift batteries with energy gently and efficiently. The user determines when charging should begin and can take advantage of favorable electricity tariffs: Peak loads and the connected load required can be reduced. The function also helps to avoid the so-called Monday effect. Thanks to time-controlled equalization charging, the battery is fully charged and ready for use after the weekend or after public holidays. This means flexibility and reliability for skilled workers. It is also possible to charge different industrial trucks on the device. The charger adapts flexibly to different forklift truck battery voltages. It detects the battery voltage as soon as it is connected and automatically regulates the current. Even deeply discharged batteries can be charged with a special refresh characteristic. Selectiva 4.0 can improve the performance of weak batteries and thus extend battery life.

Chargers established on the market

The Ri charging characteristic developed by Fronius provides users with a charging process that is as gentle on the battery as possible, prevents overheating and thus the premature ageing of lead-acid batteries. The resulting energy savings also promote visible energy efficiency compared to 50 hertz technology. Thyssenkrupp Plastics has also been impressed by this innovative charging technology. The Fronius Selectiva chargers have successfully established themselves on the market over the past ten years, impressing with individual charging curves and saving energy and costs. With the flexible Ri charging process, Selectiva 4.0 battery chargers achieve an overall efficiency of up to 84 percent.

Safe operation of the chargers

To simplify handling, Fronius has equipped the chargers with additional functions. For example, a blue LED display indicates a charged and cooled battery. Thanks to these illuminated strips on the chargers, which are visible from a distance, employees at the Tornesch site can see at a glance when which battery is ready for use again. The smart station virtually eliminates operating errors caused by incorrect assignment of battery and charger. The external start/stop function prevents sparks from forming if the charging plugs are disconnected during the charging process. This reduces the risk of an explosion.

Individually configurable loading rack solution

Safe handling of the charging plugs is made possible by spring balancers on swivel-mounted outriggers. The cables are attached to these - far away from the battery's Ex zone. Impact protection strips prevent collision damage to the stations. An individually configurable loading rack solution is also in use, which ensures greater safety in the logistics hall in Tornesch. Thanks to practical perforated plates and brackets, the specialists can also attach third-party devices to it.

The Fronius solution impressed the management and employees of Tiessenkrupp Plastics across the board. The company has now been using the Selectiva 4.0 device charging process for more than a year; it contributes to greater sustainability with energy savings of up to 30 percent.