Mahle relies on lithium-ion technology

The Still battery management system protects the batteries by balancing and equalizing load peaks. Lithium-ion batteries can last up to twice as long as lead-acid batteries. © Gerd Knehr

Mirko Strobel, International Key Account Manager at Still in Stuttgart: "We have been working with Mahle for a very long time - since 2018 even exclusively for the entire Group - and have 1,000 industrial trucks in use nationally and internationally. To maximize the availability of the forklift fleet in Schorndorf, we have equipped most of them with lithium-ion batteries." Fabrizio Ruggiero, Head of Operations at Mahle Aftermarket, adds: "Thanks to the higher availability of the lithium-ion vehicles, we can make intensive use of our fleet in our day-to-day business."

All voltage classes are used at Mahle: 24 volts for warehouse trucks, 48 volts for electric forklift trucks and 80 volts for large narrow-aisle forklift trucks. Terminals and scanners are also supplied with power.

Lithium-ion technology: more power, lower operating costs

Still's lithium-ion technology forms a complete system in which vehicles, batteries and chargers are optimally matched to each other. Depending on the existing energy infrastructure, Still chargers can achieve a charging current of up to 375 amps, which is ideal for shorter charging times in particular. This allows fast and frequent interim charging during breaks - directly at the place of use. Fabrizio Ruggiero: "Still has adapted the capacity and size of the lithium-ion batteries to our energy network." Full power is always available, even when the battery's charge level is low. A decisive advantage during order peaks, emphasizes the operations plant manager.

Still lithium-ion batteries provide twice as much energy as comparable lead-acid batteries - and always deliver full power. On the one hand, they are therefore more energy-efficient, and on the other, there is no need for time-consuming maintenance. In addition, the batteries can remain in the vehicle during the charging process and, unlike lead-acid batteries, do not need to be replaced. With a separate charging access (as a customer option) on the large MX-X narrow-aisle trucks, the battery door no longer even needs to be opened for charging. Fabrizio Ruggiero sums up with satisfaction: "By eliminating the need to change batteries, we no longer need ventilated changing zones. It also frees up valuable storage space. The entire handling of the charging processes has become safer and easier without the acids and their outgassing. This has enabled us to effectively save operating costs and a lot of time."

Smart battery management: more safety, longer service life

The Still battery management system is designed to ensure optimized coordination of vehicle control and battery management. It compensates for load peaks and always ensures a good energy supply. This protects the battery and extends its service life. Holger Betz, Regional Service Manager at Still: "The charging process of our lithium-ion batteries is safe together with the assigned charger. We always offer 'pairs' of battery and charger. This ensures that charging is not carried out incorrectly. The lithium-ion battery and charger form a perfectly coordinated energy system."

The lithium-ion battery tells the charger how the charging process should be carried out. If limit ranges are reached or are present, the charging process is either interrupted or not started at all. "Thanks to the efficient and gentle charging processes, our lithium-ion batteries can manage up to 4,000 full charging cycles," explains Betz. The vehicle batteries are recharged during the lunch break and at night. Thanks to the large battery capacities, a single charging process is sufficient for an entire shift.

Still lithium-ion batteries are a very good solution for all storage environments where space is at a premium and safety requirements are high. Chargers are installed in a decentralized and space-saving manner - without the need for battery changing rooms and corresponding accessories. In addition, Still's innovative power storage systems with their smart battery management are more energy-efficient and have at least twice the service life of lead-acid batteries. Up to 30 percent more energy utilization can be achieved with Still lithium-ion technology. In summary, a lot of time is saved during charging processes and operating costs are reduced.

Fabrizio Ruggiero adds: "After an intensive planning and integration phase for fire protection, I am now very satisfied with the new lithium-ion technology from Still. We already have other projects in mind, such as the modernization of our automation with industrial trucks."