Automatic cable pulls retract the charging cables as soon as they are no longer needed - this protects them from damage. © Fronius

"Energy efficiency and battery life are often the key arguments for our customers when it comes to investing in charging technology," explains Reto Baumgartner, Sales Consultant for battery charging systems at Fronius Switzerland. "In this case, however, the focus was on safety and user-friendliness, because the forklift fleet is not used too much." Fronius designed a central charging station with five spaces for Reishauer. "Safety distances, ventilation, signage, protective measures - there is so much to consider when planning that forklift operators often don't even know," notes Baumgartner.

Safe installation with Fronius charging modules
With the Fronius charging modules, the battery chargers have a fixed location, cannot be approached with a forklift truck and are easy to operate. Automatic cable pulls retract the charging cables as soon as they are no longer needed - this protects them from damage. The modules also provide space for all the necessary safety equipment in the event of an industrial accident. "The station not only complies with all regulations, it also looks extremely presentable," says Oliver Ritter. "It fits harmoniously into the overall picture."

The new Fronius devices are from the current generation of the Selectiva product family and use the Ri charging process. "Each charging process takes place according to an individual characteristic curve, which is calculated based on the age, capacity and state of charge of the connected battery," says Baumgartner. This is energy-efficient and protects the expensive batteries. "Thanks to automatic voltage detection, the devices can also charge different batteries flexibly." The forklifts at Reishauer use energy storage systems with 24, 48 and 80 volt operating voltages. Nevertheless, employees can connect any vehicle to any charger. "All you have to do is plug it in and the rest takes care of itself," says Ritter.

LED strips on the devices indicate at a glance whether the attached battery is fully charged and has already cooled down. © Fronius

Delayed charging, take advantage of favorable electricity rates
The devices also offer other useful features - such as a delayed charging start: no matter when an employee connects a battery, the charging process always starts at a predefined time. "This allows us to take advantage of the cheaper night-time electricity tariffs and save costs," explains Ritter. As the utilization of the fleet at Reishauer is not particularly high, it is sufficient to charge the forklifts at night so that they are ready for operation during the day. LED strips on the trucks indicate at a glance whether the attached battery is fully charged and has already cooled down.

Reishauer is also particularly satisfied with the comprehensive service provided by Fronius. "We received first-class support from the initial calculation through to the actual planning, installation and commissioning," says Ritter. "Even now, the Fronius experts are always available to answer questions, and device updates and new characteristic curves can be easily installed via a USB interface." And the logistics manager has noticed another change: "The water consumption of the batteries has fallen massively, we have to refill them much less often." An additional effect of the gentle Ri charging process that benefits Reishauer's employees in their daily work. as