EV technologies in Working Machinery –Global view Finpro 2010 1 Contents • • • • • • • • • • • • • • • • Executive summary 3 Methodology and definitions 4 Differences of electrified machinery vs. vehicles 5 Global machinery market 6 Key trends – heavy machinery 7 Development towards EV technologies 8 About key drivers and regulation 9 Emission standards and incentives 10 Bottlenecks and obstacles of development 11 Summary key industries possibilities 12 - 18 Common development strategies of companies 19 Limiting factors concerning speed of development 20 Implications of development for Finland 21 Electric mobile machinery examples from Finland 22 Company cases / examples of developed technology 23 - 51 Examples of present or potential (H)EV machinery producers 52 - 62 • Agriculture: tractors, harvesters, etc. • Forestry: harvesters, forwarders, bundlers, skidders, etc. • Mining: Miners, borers, drilling systems, loaders, dozers, conveyers, handling and moving equipment • Construction: platforms, lifting equipment, etc. • Material handling: forklifts, tow tractors, conveyers • Logistics (excluding electric cars for consumers or public transport): urban delivery vehicles, etc. © Finpro 2 Executive Summary • • • • • • • • On the surface level drivers for electric solutions in mobile machinery are partly the same as concerning e.g. public transportation and EV trucks or even cars: lowering emissions, regulation from international and national organizations and public image On the other hand they are quite different with a closer look: • e.g. EU or US legislation do not yet impose large problems concerning emissions –diesel engines can be developed to meet the set limits in short term and adapted to use biofuels. In longer term the challenges will push more for leaps in technology • Old drivers of limiting emissions and noise for e.g. using machinery indoors or in mines are valid as for decades before • Energy efficiency is a key for machinery working in limited space even outdoors (logistic centers, harbors, warehousing, or even construction) There are projects focusing on electric power sources, but more common are tests and pilots as well as R&D focusing on hybrids Most companies are interested in (H)EV topics, but machinery companies are not too active in own research, most companies look for the developments in their suppliers For electric solutions the lighter machinery like forklifts use battery power and the heavier like cargo cranes or construction machinery rely on cabling to fixed power source Major bottlenecks are the costs and reliability of the new solutions as well as technical issues like the durability and size of batteries Massive usage of pure EV-propulsion will not be feasible economically before battery and/or SuperCap performance has radically increased (cost efficiently) Sector offer opportunities for Finnish companies and there is a lot of potential for R&D activity, but also governmental / regulatory actions in pushing end client demand forward © Finpro 3 Electric mobile work machinery – methodology and definitions This report is based on best available information gathered by Finpro consultants during summer and autumn 2010. Information was gathered by market expert and industry interviews mainly in EU, USA and Asia (South-Korea, Japan and China). Most interviews were done as part of other work or e.g. during exhibitions or industry events. As the interviews did not reveal too specific understanding about the present trends and specifically most companies were quite secretive about their plans, the study relied much to secondary and public information in e.g. industry publications and Internet. Electric machinery is not a new invention as electric motor was invented and much developed in the 19th century. The applications vary from wrist watches to ships and airplanes. As this brief global study can not even scratch the surface of all the possibilities, we focused on the most relevant (and visible) solutions available and developed in Finland. Primarily we focused on machinery meeting the following criteria • Mobile machines gaining power from battery (electric source) • Working performance provided by source of electric energy • Mobility assured by own forces From the key industries: • Agricultural and forestry machines • Mining and construction related machinery • Material handling equipment and machinery Solutions requiring cabling or trolley solutions are not dealt as pure EV solutions within the above definition, but are taken into account due to being complementary solutions. Hybrid solutions were handled partly as EV technologies and seen as of major alternative for pure EV solutions –especially until the battery capacities can be significantly increased. Until fuel cells or passive energy sources are feasible diesel based hybrids will be a intermediate solution. © Finpro 4 Key differences of electric mobile work machinery to electric vehicles • • • • • • • Production series sizes are significantly lower: typically some hundreds to thousands Size of the machines varies from light forklifts and agrimachines to huge construction machines (some hundreds of kilos to tens of tons) Work tasks and purpose of the machines vary hugely Work environment varies: indoor, mines, agricultural fields, forests, industrial and logistic centers, etc. Required power varies much more: from about 10 kW to MW class machinery High force, performance and torque are typical requirements but actual speed of moving the machinery/ transport speed is typically low Electric propulsion is common/ business as usual in certain areas (specifically light or very heavy machines and machines used in confined spaces) © Finpro 5 Global Machinery Market • • • • • There are various estimations on the total value of the market depending on definitions of the group. Figures below represent overall classifications, not specifically mobile machinery. However the total market for machinery for specified sectors is about 430 billion euros annually. • Production of agricultural and forest machinery is estimated to exceed 120 billion euros annually • Production of mining and construction machinery exceeds the value of 150 billion euros annually • Production of lifting and handling equipment about 150 billion euros annually in last two years • Asia Pacific is the most active production region for all categories above with some 60-70% of total production • About 50% of the production is placed in developed countries and 50% in emerging and developing countries • Recently the development and growth has stopped, but is expected to gain speed in 2011 and going back to 5-10% annual growth. In any case the total market for these technologies is vast and large enough in any general measures. However, the market is fragmented as special purpose machines are in many cases becoming more and more specialized or alternatively there is a strive for multipurpose machines Different rental and leasing models are changing the end-users business models especially in construction business and e.g. strengthening the possibility of using more special purpose machines The share of EV technologies varies hugely from sector to another. Easiest to estimate is the forklift business sector, where about 50% of machines used in developed countries is electric due to requirements of eliminating exhaust gases and noise. In most other segment the share of electric solutions is very limited and similar to electric vehicle sales the actual amounts sold are still minimal and targeted only to niche clients © Finpro 6 Key Trends – Heavy Machinery Manufacturers are slowly beginning to replace traditional mechanical and hydraulic systems in construction gear with hybrid-electric drives that improve efficiency, simplify the structure of machine and lower operating costs. A growing demand for machines that cost less to operate, together with regulatory pressures for lower emissions, are leading construction-equipment manufacturers to electric and hybrid drives over traditional hydraulic and mechanical ones. Hybrid drives typically let OEMs use smaller diesel engines and operate them at speeds where they are most efficient and run cleaner (with less emission). And the drives can recover and reuse energy that was previously wasted as heat — which means smaller cooling systems. But the key advantage is lower fuel consumption over machines with moreconventional powertrains (e.g. up to 25% in case of hybrid excavator) — which saves money and lessens environmental impact. And hybrid machines can offer productivity gains and often require less maintenance. Although this is still an extremely small segment of the overall industry, this report portrays cases of several leading companies in the global market which are also leading the way in terms of electric drive and hybrid technology for the heavy machinery industry. © Finpro 7 Development towards EV technologies In general the enthusiasm to develop EV technologies is much lower in machinery sector than in electric vehicles • The companies are either not interested in the development or see it as a competitive factor and are not willing to discuss their views on development • As the variety of machinery is vast there are not simple and clear development trends. No clear prioritization of technologies or development paths can be generally discussed. • When preparing any new products development plans for this segment, companies should focus on the end client market and verify the willingness to adapt new technologies and especially the willingness to pay more for these General observations by Finpro: • Cable and trolley/rail solutions are common areas of development in more stationary and heavy machinery • Pure electric (fully electrified) work machines are rare except in forklifts and mining solutions as well as very specialized and heavy machinery (where the power requirements push towards cable solutions) • Hybrid solutions seems to be a popular research topic as most recent new product launches concerning EV in work machinery are related to hybrids. • However, the ongoing industrial R&D was proven to be very difficult to map as co-operation with public/ open projects is rare and most companies are developing their technologies inhouse – which is a trend strengthened by the global downturn as companies • The development is much more visible in the automotive and truck industry where hybrids systems are often object of intercompany trading –e.g. buying whole hybrid divisions (Dana>Bosch). Simply put the development of electric mobile machinery is still in many areas in early stage and the directions it will take and the volumes are impossible to evaluate accurately • Electric solutions have been popular research topics in e.g. military applications, but even there the trend seems to be more towards hybrid solutions at the moment • Excavators, forklifts, wheel loaders and medium heavy machines seem to be the most common type of work machines to be developed to a hybrid version. • © Finpro 8 About key drivers and regulation Common drivers of development, which are also shared with electric vehicles: • Low emissions and noise • Cost savings (life cycle costs and maintenance) • High performance solutions • Fuel efficiency • Structure and production simplification • Life expectancy of machinery • Green values • Regulation Regulation: • Emission standards for non-road diesel engines: EU and US EPA • NOx, HC, CO2 – continuous restriction via emission norms © Finpro 9 Emission standards and incentives European Union regulations for emission standards for diesel engines other than constant-speed engines to be installed in non-road mobile machinery. P [kW] 2009 2010 2011 2012 P < 19 2014 2015 2016 2017 Stages: No limits 19 < P < 37 37 < P < 56 2013 Stage IIIA 5,5 / 7,5 / 0,6 5,0 / 4,7 / 0,4 5,0 / 4,7 / 0,025 56 < P < 75 5,0 / 4,7 / 0,4 5,0 / (0,19+3,3) / 0,025 5,0 / (0,19+0,4) / 0,025 75 < P < 130 5,0 / 4,0 / 0,3 5,0 / (0,19+3,3) / 0,025 5,0 / (0,19+0,4) / 0,025 130 < P < 560 3,5 / 4,0 / 0,2 3,5 / (0,19+2,0) / 0,025 Stage IIIB Stage IV Limit values: [g/kWh] CO / (HC + NOx) / PT 3,5 / (0,19+0,4) / 0,025 Source: A. Hentunen, J. Suomela, A. Leivo, M. Liukkonen, and P. Sainio, Full-Scale Hardware-in-the-Loop Verification Environment for Heavy-Duty Hybrid Electric Vehicles, The 25th World Battery, Hybrid and Fuel Cell Electric Vehicle Symposium & Exhibition, EVS-25, Shenzhen, China, Nov. 5-9, 2010 • • • • US EPA Tier regulations are similar to EU limits Emission limits are tightening in the future for engines bigger than 37 kW However, EU directives include so called flexibility schemes, and the flexibility meaning possibilities to use previous periods limits temporarily is planned to be widened (proposal has been made 7.7.2010) Compared to electric commercial vehicles there is a clear lack of financial stimulus or other incentives for the utilization of alternative technologies of the diesel engines © Finpro 10 Main bottlenecks and obstacles of development from perspective of industry • • • • • • • Price increases of machinery due to applying new technologies – even with estimated lower life cycle costs/ operational costs the higher price is a problem in highly competitive industries In most cases the end users come from very traditional industries that have used traditional technologies for decades. For these end users the purchase of new machinery represents significant investments and it is unlikely they are willing to be early adopters / testers of new solutions without incentives from government Green image is not yet a large selling point in industrial machinery sector or at least companies are unwilling to pay significantly more for this Battery technologies are not seen as mature in industry and possibilities for developing full electric solutions are limited by the low storage capabilities of the batteries. Battery technology challenges include weight, fast charge, dimensions and price. Availability of components now and uncertainty about the future availability limit the motivation of OEMs to implement EV technologies. Motivation can be also affected by the need to restructure supplier base if key technologies are changed. Most producers see the sector risky as new product development takes few to several years for engineering and prototyping and raking new technologies into the equation simply increases the risks of companies. Many of the potential machinery are used in areas or even countries with poor service networks and operators have limited technical skills. High technology solutions are then seen as a risk or practically impossible to use. © Finpro 11 Summary key industries possibilities Industry Typical solutions Future options Agriculture and forestry Electric drive uncommon. Some hybrid pilots done. Electrification of smaller machines and especially machinery for janitorial municipal segment, hybrid solutions for meeting the future emission limits of diesel engines. Harvesters in forestry offer possibilities for hybrids. Mining machinery Electric drive common in underground operations. Mostly cable or rails solutions. Also open mines with cable solutions due to fire hazards (e.g. coal mining). Potential for both hybrid and pure EV solutions Construction machinery Electric powered machinery usually relatively stationary. Many solutions available also with cabling. Lighter/ janitorial equipment have large potential for electric solutions. Hybrid solutions may have potential in several areas as the variation of machines is vast. Material handling Smaller applications (inside buildings) are electric by definition like forklifts. Larger material handling equipment in logistics centers and ports can be a growth area. Sector is largely familiar with EV technologies and development will continue. © Finpro 12 Summary of Agricultural Machinery Sub Group of Agri Machinery Current typical solution / nowadays trend Future options Examples of companies Key drivers for development Small farm vehicle / park Main power source is machines petrol or diesel engine High potential for electric solution New large grass cutter by John Deere with hydraulic transmission Simplification of construction, higher agility, performance, green image in solutions used e.g. in municipal environments Harvesters Due to high and constant performance demand, diesel engine, seems to be the only alternative Potential for hybrid solutions, but likely a follower area (will adopt technologies only after proven in other areas) Thrash "hybrid" system with non parallel drum axis by Class and Massey Fergusson Simplification, flexibility of construction, higher reliability. Lowering performance costs. Tractor ICE and specifically Electric solutions are diesel engines) remains restricted by battery the main power source technology, potential due to need to supply electricity to equipments attached New Holland NH2 Hydrogen Tractor. Consumption reduction due to operation in ideal revolution, using smaller engines. Lowering performance costs. © Finpro John Deere 7030 E Premium tractors feature integrated electrical distribution and power management system that can drive electric and hybrid implements. 13 Summary of Forest Machinery Sub Group of Forest Machinery Current typical solution / nowadays trend Future options Harvesters Diesel engine - main power source, propulsion by shaft or hydro-motor. Eco standards reached by using bio-fuel and non synthetic hydraulic fluids Equipment and manipulators powered by electro motor /hybrid solutions Probable development direction, but no public information available. Flexibility of power transmission. More efficient use and lowering fuel consumption. Lowering performance costs Forwarders Diesel engines. No major trend for electric solutions Hybrid drive system El-forest F12/F14 has a Hub engine in each wheel Consumption reduction, structure simplification, work environment, Lowering performance costs © Finpro Examples of companies Key drivers for development 14 Summary of Material Handling Equipment Sub Group of Material Handling Machinery Current typical solution / nowadays trend Future options Examples of companies Key drivers for development Indoor Fork lifts are regularly electro powered E-engine, on board battery loader, guiding systems, hybrid propulsion Outdoor / heavy Fork lifts are optionally electro powered. E-Propulsion, 80V board Zeppelin J2.2-3.5XN net. Hyster 3.5 tones Work environment, noise reduction. Heavier equipment like container handling and equipment used in logistics hubs is predominantly diesel powered. Hybrid or diesel electric Kalmar hydraulic hybrid solutions followed by drive terminal tractor. fuel cell driven hybrids or electrification of medium heavy solutions working in smaller areas (like ports or logistics centers). Fuel economy, lowering performance costs. © Finpro Rocla, Jungheinrich, Work environment, Toyota, Nissan, etc. noise reduction, exhaust electric fork lift systems. elimination 15 Additional information about forklift industry As forklifts are probably the best known for their electric drives, below are some key notifications of this industrial area: • The forklift industry is broken down into five classes of machines, as listed by the Industrial Truck Association (ITA), with some manufacturers selling models in all five or specializing in just a few. • The forklift market is also differentiated by the type of propulsion system-electric drive or internal combustion engines. Electric units make up about 60% of the market. The trend towards electrics can be attributed to ever-tightening engine emissions requirements and technology advances in performance and efficiency of electric drives and batteries. • Approximately 60% of lift trucks sold today have a battery, and that trend is expected to continue over the next several years. • A number of manufacturers compete in the forklift market. Some of the major players include Mitsubishi Caterpillar Forklift, Toyota, Nissan, Hyster and Yale. • Battery technology has also advanced the trend toward electric-powered forklifts as the cost and performance of batteries continue to improve. Forklifts are also proving to be fertile ground for the advancement of hybrids, fuel cells and other alternatives. © Finpro 16 Summary of Construction Machinery Sub Group of Construction Machinery Current typical solution / nowadays trend Future options Light There are several light machines utilizing electric power (e.g. lifting platforms, reachers, etc), but most mobile machines are still diesel powered Propulsion system of upper structure, usually powered by hydromotor. Komatsu hybrid system Consumption reduction recuperates energy by (25% in average), work slowing down of upper environment structure turning, charge capacitors and re-use by accelerating Heavy Due to high performance demand and mobility, diesel engine remains main power source. However the heavier machines can be also cable/net charged Hybrids may offer many options for making the machinery more economical and environmentally friendly. Battery capacity will limit development of EV solutions in heavier machines if cabling is not possible to utilize. Caterpillar: Diesel/Electro powered dozer CD7e El. generator-motor pair works similar to CVT. Volvo L220 wheel loader powers. © Finpro Examples of companies Key drivers for development Fuel consumption. Emission limits in the future. 17 Summary of Mining Machinery Sub Group of Mining Machinery Open mine Deep mine Current typical Future options solution / nowadays trend Cable solutions are best Drive system practice, but also diesel Cable (trolley) vehicles (loader), battery hauler, Drive system © Finpro Examples of companies Key drivers for development Large excavator by Liebherr Higher effectiveness, ease access to el. Current, fire risk minimization Exhaust elimination Joy electro powered hauler with battery Sandvik mining loaders 18 Common development strategies in machinery Based on interviews in the market and Finpro observations of company behavior, it seems that there are three main strategies that are being followed by different companies concerning the EV technologies: 1. 2. 3. Pioneer/ integrated developer Follower / Supplier focused Not active First group has typically large own resources and has activities within the group for motor or engine development. Companies like this seem to be active e.g. in hybrid development or at minimum having some R&D projects in-house and finally aim at offering wide spectrum of own or supplied solutions. Second group doesn’t in most cases have any electric solutions at the moment, but some of them already offer solutions for alternative power and drivetrain. They may e.g. rely on their powertrain suppliers for the development of hybrids or they offer their products with the alternative of cabling. Third group is not actively doing anything presently concerning EV. They may have alternative development focus such as biofuels or improving their diesel efficiency. They may even follow the general development, but see the drivetrain development as the problem of suppliers or a problem for the future –not a present issue. © Finpro 19 Key limiting factors concerning the development • • • • • • Besides electric power and hybrid solutions as well as diesel electric solutions, most of the companies will have possibilities to keep up with the environmental demands of both regulators and increasing fuel costs by focusing on better efficiency and improved technology as well as solutions combining biofuels and alternative fuel sources to their machinery. Concerning electric systems the capacity and lifetime reliability of the batteries is a main issue. Naturally applications which allow usage of cabling are possible, but otherwise the large scale adaptation of EV technologies in heavier work machines, which must have long work cycles, is not feasible –especially when battery costs are high Uncertainty of what type of technologies will be winners in the long-run create risks for companies and reduce the willingness to invest in new product development in early phase. Especially the role of fuel cells and super capacitors seems to be unclear Many of the machinery companies do not have a lot of in-house resources concerning the EV or hybrid solutions and it is not clear where to get the correct resources or to whom to partner up with One of the main limiting factors of the speed of development is the lack of end user demand in most industries. Why would an industrial client select a more expensive technology that is not proven and tested in industrial use for decades? In many cases machinery companies (OEMs) have moved more towards services and offer both spare parts and maintenance of the machinery as part of their business. As the electric solutions are expected to be more reliable and to have less wearing parts, it may be that moving to electric solutions will look less attractive © Finpro 20 Implications from present development strategies for Finland Following ideas are targeted at starting a discussion with Finnish industry and the innovation network and are not to be seen as fixed suggestions: • • • • • Mobile machinery offers much more potential in manufacturing and product development sector than the automotive production as the production volumes and series sizes are much smaller (and therefore more fitting to Finnish market) and there exist a wider company base already As activity in many sectors for (H)EV is limited or just beginning this may offer competitive advantage for Finnish machinery manufacturers if they focus on correct end clients and verify the demand. End client demand should be evaluated and understood better before taking decisions R&D in the area should be supported by state activities, if Finland is to be competitive in the future, but there is also need to develop the end client demand and awareness. In fact as there seems to be lack of end client demand for industrial solutions globally (in the large volumes) there may be opportunities for Finland to tempt also new investors and players to the market if the end client segment is developed faster than elsewhere. Finland offers also a good test area for new machinery due to our four seasons, well developed infrastructure, long distances and heavy industry. Besides technologies there are opportunities in developing new business models: e.g. if the sales of spare parts will decrease with selling an EV solution and the price of the battery (and it’s reliability) are bottlenecks, there can be opportunities in alternative models like selling the machine, but leasing the battery Potential for component manufacturing/ subcontracting for international companies in EV technologies is presently limited, but offers potential in the future. • Key issue will be to identify pioneers and open discussion in early phase. However, as the largest companies seem to be doing the development almost purely in-house, it may be difficult to even open discussions at this phase • Larger suppliers of the machinery industry were not mapped for this study, but this segment may offer possibilities to component manufacturers © Finpro 21 Electric mobile machinery –examples from Finland • • • • • • • • Acgo Sisu Power, http://www.agcosisupower.com/products/generating_sets_and_pump_sets/generating_sets • Diesel engines, diesel generators and pumps, gear wheels and gearboxes • Continuous improvement of diesel engines fuel efficiency (optim. Combustion), exhaust gas (SCR catalyzer) John Deere Forestry, http://www.timberoffice.com/english/company/ • Harvesters, Forwarders, Heavy Forestry machinery, agriculture machinery in general • John Deere Construction & Forestry Hybrid Electrification http://www.elmia.se/en/wood/press/fair-news/john-deere-puts-its-foot-downbrthe-future-is-electric/ • still developed / technology presented in 2009 Ponsse, http://www.ponsse.com/english/products/harvesters/index.php • Forestry machinery of all kind • No publicly known interest and focus for EV sector Sandvik mining, http://www.miningandconstruction.sandvik.com/ • Machinery for deep -, surface mining, construction, tunneling etc. • Electro powered deep mining loader… • On market since 2010 Patria, http://www.patria.fi/Patria_WWW_EN_Sisalto/Patria_WWW_EN/Products+and+services/index.html • Airport equipment, Military vehicles, Aero structure … • Electro – hydraulic propulsion for Armored vehicles • On market since 1997 Cargotec, http://www.cargotec.com/cms/cargocms20.nsf/Documents/B80F817D8C7E1D4BC2256FDB003E4CC0?openDocument&lang=1 • Heavy load handling machinery, cranes … • Semi – Stationary machines find the EV - propulsion • On market since 1977 Rocla, http://www.rocla.com/sectionpage.asp?Section=2872 • Load handling machinery, forklifts, automatic logistic systems • EV used for forklifts and tow car powering, AGV automated guided vehicle • On market since 1967 Avant-tecno, http://www.avanttecno.com/www/index.php?PAGE=248&NODE_ID=248&LANG=2 • Wheel loaders under 2 Tones • EV-technology used for in door solutions • On market since 1991 © Finpro 22 Example cases: Agco Sisu Doosan Caterpillar Daimler Dana Doppstadt Eaton Hitachi Hyundai John Deere Kalmar Komatsu Kopex LeTourneau Technologies Liebherr Manitou New Holland Nissan Forklift Mecalac Ahlmann Rocla Sandia Same Deutz-Fahr Sennebogen STILL Toyota MH Volvo Construction Company case: Agco Sisu Power AGCO SISU POWER has made diesel engines at its plant in Linnavuori in the town of Nokia for more than 60 years. The acquisition of AGCO SISU POWER (former Sisu Diesel) made by the US AGCO Corporation and the associated investments – tens of millions of euros – have made AGCO SISU POWER one of the world's leading makers of diesel engines. In 2008 Sisu Diesel is branded AGCO SISU POWER. AGCO SISU‘s new Citius series Common Rail engines that meet the latest European and North American emission standards and their engines also can use environmentally friendly biofuels. Company employs 680 employees people in Nokia plant, which produces some 30.00 engines annually. Example: 4th generation diesel engine • Engines with SCR (Selective Catalytic Reduction) • Benefits of the SCR in Stage 3B • Up to 10 % improvement in fuel economy • Highly efficient combustion minimizes particulate emissions. Particulate filters that require regeneration can thus be avoided. • Fast load and speed response due to proven bypass turbo charging technology Technology • Sequenced injection process – The whole injection process is completely controlled by the Sisu Tronic. Injection timing, pressure and sequence are automatically optimized according to operation conditions. • http://www.agcosisupower.com/products/agco_sisu_power_engines/ © Finpro 24 Company case: Doosan Doosan is a Korean origin diversified group, with several subsidiaries and brands. Its infrastructure division consist of brands like Bobcat, Ingersol Rand, Tramac, Montabert etc. Construction division of Doosan provides to the customer large spectrum of construction machinery like excavators, dump trucks and wheel loadesr. Company employs 35,000 (15000 overseas) people world wide in over 30 countries. Example: Doosan hybrid excavator • Expected launch on American market in 2012 • The first hybrid excavator will be a 22-ton model with an approximate 35 percent reduction of fuel consumption when compared with the DX225 standard hydraulic excavator. Technology • Equipped with a diesel engine, electric swing motor, electric converter and an ultra-capacitor that will store excess energy during turning and light-duty operations • The reserve electricity (from capacitor) will be used used to assist the power of the engine during heavier work; allowing the engine to maintain low revolutions and high efficiency combustion during acceleration • Targeting at significantly reduced fuel consumption • • http://www.doosan.com/doosaninfracore/en/pressRelease.do?cmd= viewPressRelease&no=20100608182745500000 http://www.undergroundconstructionmagazine.com/doosaninfracore-efficient-hybrid-excavator © Finpro 25 Company case: Caterpillar 1/2 • • • • Caterpillar Inc. designs, manufactures, markets and sells machinery and engines and sells financial products and insurance to customers via a worldwide dealer network Caterpillar is the world's largest manufacturer of construction and mining equipment, diesel and natural gas engines and industrial gas turbines Recently Caterpillar has announced a deal to buy Milwaukee mining equipment specialist Bucyrus International for US$7.6bn, with an eye on expanding into emerging markets like China, India and Brazil. Bucyrus manufactures surface mining equipment used in the extraction of copper, iron ore, coal, oil sands and other desirable minerals. Caterpillar said it expects its business to grow by 3.5% over the coming year Example: Caterpillar D7E bulldozer • Caterpillar‘s flagship so far for EV has been Caterpillar D7E bulldozer, which is a diesel electric solution and they have been developing a heavy load e-truck. • For more details see: http://www.cat.com/d7e © Finpro 26 Company case: Caterpillar 2/2 Caterpillar D7E Electric drive Dozer - Peoria, Illinois Caterpillar's D7E crawler dozer is the first electrically driven dozer using modern alternating-current (AC) technology, and Cat claims it will move up to 25 percent more material per gallon of fuel than the D7R Series II. The drive system takes advantage of today's small, less-costly semiconductors that can rectify heavy-duty-drive voltage to AC, eliminating brushes. The drive is developed by Caterpillar specifically for crawler tractors. Caterpillar claims its 60,000-pound-weight-range D7E crawler dozer‘s innovative electric drive system will deliver 25 percent more material moved per gallon of fuel than the D7R Series II. A 235-horsepower Cat C9 diesel drives a generator to produce electricity that ultimately powers two AC electric drive motors, which are connected to a differential steering system, final drives, and a low-sprocket undercarriage. The electric drive train has 60 percent fewer moving parts compared to previous D7s. The system also provides power to auxiliary components, eliminating engine belts. The D7E is the first electric drive dozer using modern AC technology, and the drive is developed by Caterpillar specifically for track-type tractors. The drive eliminates gears to shift, and is said to perform much like a hydrostatic drive, albeit with faster response to load demands. The D7E became commercially available in 2009. Currently, Cat is the only US manufacturer with an electric-drive heavy machine on the market. © Finpro 27 Company case: Daimler Daimler is the world leader in production of BlueTec diesel engine for Trucks and with the brand Detroit Diesel offers high quality engines in USA Company employs 260,000 people in more than 140 countries world wide, Head quarters is located in Stuttgart, Germany. Example: Blue Tec diesel engine • • • • BLUETEC combines optimized combustion with special exhaust gas after treatment, known as selective catalytic reduction (SCR). Since the market launch of BlueTec in 2005, more than 210,000 trucks and buses equipped with this technology have been put on the road http://www.daimler.com/dccom/0-5-1200798-1-1202000-1-0-0-1200840-0-0-135-7165-0-0-0-0-0-0-0.html http://cars.about.com/od/thingsyouneedtoknow/a/ag_BLUETEC.htm Example: Mercedes-Benz Atego BlueTec Hybrid Medium duty truck combines advantages of BlueTec clean diesel system with paralle Hybrid equipted with Li-Ion battery http://www.daimler-technicity.de/atego-bluetec-hybrid/ Roland Dold developed the Mercedes-Benz Atego BlueTec Hybrid in the Predevelopment department. © Finpro 28 Company case: Dana Dana corporation has a hundred years long history and the company is a sub-system supplier for automotive and machinery industry. Company employs about 22,000 people in nearly 100 facilities world wide. Head quarters is located in Maumee, Ohio. Company is focused on North American (51%), European (23%), South American (15%) and Asian Pacific (11%) market. There are negotiations between Dana and Bosch corporation about purchase of the hybrid division of Dana. Example: Dana Holding Corp.‘s Off-Highway Products Group New hybrid drivetrain: Spicer TE-15HX electric parallel hybrid • Dana introduced the Spicer TE-15HX transmission at the recent Intermat show in Paris and in Bauma 2010. The hybrid transmission is designed to improve fuel economy and vehicle productivity and reduce emissions. • It‘s in response to the global construction market‘s renewed emphasis on fuel -efficient equipment that will not compromise productivity or reliability, according to a company spokesman. The concept transmission is an electric-parallel hybrid featuring controls that continuously monitor operating conditions and selects the best combination of diesel and electric power for performance at the lowest fuel consumption, emissions, and noise. • Whenever possible, the TE-15HX controls disengage the diesel engine and takes power from supercapacitors for inching and other vehicle operations that consume little energy. It also powers lights, climate control systems, and other electrical accessories. Under light loads, the diesel engine alone powers the vehicle while the generator charges the supercapacitors. Regenerative braking is also an important source of energy for recharging capacitors. When applications call for more traction, the electric drive functions as a motor and provides power for added torque and faster take-off. Application of Technology/ plans for use • Targeted for material-handling vehicles, Dana is evaluating three and four-speed versions of the TE-15HX transmission with estimated ratings of 110 to 175 kW (147 to 235 hp) • Suitable for usage in several heavy construction machines. • http://www.dailynews-online.com/bauma/story/components-and-attachments/the-spicer-te-15hx-is-an-electric-parallel-hybrid-system-thatis-being-unveiled-by-dana Example: Fuel cell integral parts The Dana Fuel-Cell Products Group is a world leader in the development and manufacture of fuel-cell stack, balance-of-plant, and fuelprocessor (hydrogen generation) components and sub-systems for automotive, industrial mobility, portable, and small stationary applications. It has R&D centers in Canada, Germany, Japan, and the United States. Trade names include Victor Reinz® bipolar plates; and Long® heat exchangers. http://www.dana.com/wps/wcm/connect/dext/Dana/Markets/Light+Vehicle/Fuel+Cells/ http://www.h2fc-fair.com/hm09/exhibitors/dana.html © Finpro 29 Company case: Doppstadt • • • • Doppstadt is a modern enterprise with long tradition in technolgy and machinery. In 1965 Werner Doppstadt founded an agricultural company at Velbert, which today is one of the worldwide leading partners in the field of environmental technology. Company develops, manufactures and sells stationary and mobile machines for waste management. Main products are stationary and mobile recycling machines The series of shredders also includes semi trailers, stationary machines and tracked vehicles. Example • Most products are available in different classes are available with both diesel engines or electric drives • The efficient mechanic power transmission is carried out by a direct drive with planetary gear • Electric drives are available both with AC and DC motor (AC e.g. in smaller shredders) • In most cases electric drive is used with stationary machines of Doppstadt • www.doppstadt.com/ © Finpro 30 Company case: Eaton Eaton Corporation is a diversified power management company with 2009 sales of $11.9 billion. Eaton is a technology leader in electrical components and systems for power quality, distribution and control; hydraulics components, systems and services for industrial and mobile equipment; aerospace fuel, hydraulics and pneumatic systems for commercial and military use; and truck and automotive drivetrain and powertrain systems for performance, fuel economy and safety. Eaton has approximately 70,000 employees and sells products to customers in more than 150 countries. Headquarter is located in Cleveland, Ohio. Example: Hybrid power system • Eaton corporation developed hybrid electric and hybrid hydraulic transmission systems • The system can achieve up to 60 percent reduction of fuel consumption especially in stop-n-go mode of city cargo trucks. • • • • • Technology The Eaton system is a parallel setup, that includes an automatically control manual transmission, 44kW motor with 420 Nm, and a 2kWh lithium ion battery pack. The engine is connected to the motor via a clutch and always runs during operation, to power the non-electrical accessories. The motor and battery drive the transmission. When the battery gets low, the clutch connects the engine to the motor, to charge the battery and drive the vehicle http://www.eaton.com/EatonCom/ProductsServices/Hybrid/SystemsOverview/HybridElectric/index.htm http://green.autoblog.com/2007/02/10/eaton-will-start-production-of-hydrid-drive-system-for-medium-du/ © Finpro 31 Hitachi Construction Machinery • Part of Hitachi Group –multi industry and sector holding including IT, biotechnology, and nanotechnology. The group is active also in the energy and infrastructure sector and has announced e.g. cooperate with Chinese government in developing Dalian city. Developments include energy-efficient smart-grid. They are also active in production of lithium-ion batteries. • Hitachi Construction Machinery (HCM) develops, manufacture and sell excavators, wheel loaders, off-road dump trucks, tunnel boring machines and other products. Example: • HCM and its subsidiary TCM developed Hybrid Large Wheel Loader (L130) with a bucket of 13m3 in November 2008. • L130 wheel loader incorporates an electrical drive system, which was developed by utilizing Hitachi Group's motor inverter technology, and a capacitor that is charged with electricity generated while reducing speed for use when starting and accelerating. These features increase fuel efficiency by 30% comparing to a wheel loader with a torque converter, according to calculations. • TCM will continue to develop construction machines that run on less fuel to contribute to the prevention of global warming. • For more information see: http://www.hitachi-c-m.com/global/index.html http://www.hitachi-cm.com/global/company/csr/environment/research/loader.html © Finpro 32 Company case: Hyundai • Hyundai Heavy industries is a Korean corporation operating in diversified sectors. The group is also known for their automotive production and e.g. hybrid development seems to be more active in that part of the corporation. Its construction equipment division has developed 92 independent models of supplies e.g. different types of wheel loaders and excavators. Example: Hyundai hybrid excavator • • • • • • • • 22 tones hybrid excavator prototype will be putted into full production in 2011. The company also plans to introduce heavier models in subsequent years. Technology Result of a three-year development program. It features an electrical system alongside a traditional diesel engine that captures energy from the braking of slewing movements and movements of the boom, and stores this energy The use of energy to run machines can cut the excavator's fuel consumption by 25%. http://www.hyundai-ce.com/ http://www.khl.com/magazines/internationalconstruction/detail/item58512/Hyundai-unveils-hybrid-excavator/ © Finpro 33 Company case: John Deere Forestry John Deere is a global leader with some 50.000 employees around the world producing machinery and equipment for residential, commercial, golf, agricultural, construction and forestry sectors as well as development of own engines and drive trains. Forestry division has also a long history and offers e.g. harvesters, forwarders, equipment and large specter of services for forest machinery. Example: New hybrid drive train concept for forestry machines • • • • • • • • • • • • JD‘s hybrid electric drive train concept designed for Deere‘s equipment divisions. System was presented on Elmia Wood 2009. Benefits of new system. System presented at Elmia Wood can reduce fuel consumption by 15 to 25 percent at a constant engine speed. The power train has s simpler mechanics, which cuts maintenance costs and increases machine reliability. New development: Diesel engine is connected to a generator which powers a transfer box for the wheels. Using a transfer box means that the new power train can be used in existing forest machines. John Deere is also developing a version with electric motors in the machine‘s wheel hubs. http://www.elmia.se/en/wood/Press/Exhibitor-releases/John-Deere-introduceshybrid-electric-drive-train-concept/ http://www.deere.com/en_US/cfd/forestry/deere_forestry/info_center/about/miles tones.html © Finpro 34 Company case: Kalmar The company Cargotec provides machinery and equipment for harbors under its brand name Kalmar. Cargotec‘s drive to reduce fuel consumption and emissions using hybrid technology has been underway for some time. Starting in 2008, the company was the industry‘s first to offer straddle carriers and later shuttle carriers with hybrid drive systems. Example: Kalmar hydraulic hybrid drive terminal tractor • The Kalmar hydraulic hybrid drive terminal tractor is equipped with a parallel system that simultaneously transmits power from two distinct sources – the primary diesel engine and the secondary hydraulic motor. • Parallel system allows the vehicle to work with or without its secondary power source • The new machine is the result of Cargotec‘s partnership with Singapore Technologies Kinetics Ltd • In the typical port environment, fuel savings of 20 percent and an even greater reduction of NOx and particulate matter emissions can be achieved depending on style of driving. Additional information about Cargotec: • Company is active in all sectors concerning environmentally friendly solution. E.g. MaGgregor –another division of the company has new electrically-driven equipment including cranes, rolling hatch covers, a hatch cover stacking device, and RoRo cargo access equipment • http://www.kalmarind.com/show.php?id=1317183 © Finpro 35 Company case: Komatsu Komatsu Ltd. is a diversified provider of industrial-use products and services. Key industrial areas are construction and mining equipment, but the production includes other business,such as industrial machinery and vehicles, logistics, electronics and other solutions-based operations. Komatsu is the world's second largest supplier of construction, mining and utility equipment. Komatsu invested 3.2% of their revenues into R&D in FY2009. This amounts to about 400 million euros. Komatsu develops hybrid components internally except capacitor cells. As mid-long term R&D mission, Komatsu focuses on usage of ICT technology and environment. As a leading company of the construction equipment manufacturing industry, they claim to be determined to meet the needs of the time by practically proposing innovative equipment designed to reduce environmental impact, including CO2 reduction. Examples: • Komatsu is going to launch worldwide sales of HB205 and HB215LC hybrid hydraulic excavators, initially in Japan on December 1, 2010 • Company announced in 2008 that they will launch sales of the PC200-8 Hybrid excavator, the world's first hybrid construction equipment. The PC200-8 Hybrid is powered by the Komatsu Hybrid System which uses a newly developed electric motor which turns the upper structure, power generation motor, capacitor and diesel engine. Compared with the standard PC200-8 hydraulic excavator, the hybrid model achieves about 25% reduction of fuel consumption. Komatsu introduced this hybrid excavator as it is flagship construction equipment. • In May 2007, Komatsu launched the world's first hybrid electric forklift trucks on the market. • For details, see http://www.komatsu.com/CompanyInfo/profile/randd/ http://www.komatsu.com/ http://www.komatsu.com/CompanyInfo/press/2008051315113604588.html http://www.komatsu.com/CompanyInfo/press/2009100213230107593.html http://www.komatsu.com/CompanyInfo/press/2010112911374014646.html © Finpro 36 Company case: Komatsu Americas Komatsu America Hybrid PC200LC-8 excavator- Rolling Meadows, Illinois Komatsu introduced its hybrid excavator into the North American market in November 2009. This hybrid delivers fuel savings through power and efficiency, while reducing environmental impact as compared to the standard Komatsu model. ―Komatsu‘s decision to apply its engineering excellence to the largest construction machine segment, clearly signals our commitment to developing environment-friendly equipment‖, says Dave Grzelak, Chairman and CEO of Komatsu America Corp. Occupying space in the largest construction machine segment (20 to 22 tons), the PC200LC-8 is powered by the Komatsu Hybrid System and features a newly developed electric swing motor, power generator motor, capacitor and diesel engine operating on the principle of swing energy regeneration and energy storage. Kinetic energy generated during the swing braking phase is converted to electricity sent through an inverter and captured by the Ultra Capacitor. Captured energy is discharged for upper structure rotation and to assist the engine as commanded by the hybrid controller. The PC200LC-8 is leading Komatsu‘s drive to address growing environmental concerns around the world. Tests against the standard model showed the hybrid reduced fuel consumption in the range of 25 to 40 percent, depending upon job application. © Finpro 37 Company case: Kopex group Kopex Waratah • Kopex Group, the third largest global group in the sector of mining machinery, equipment and services in hard coal, lignite and non-ferrous industries. • Kopex group has had little EV focus before they recently acquired Australian mining technology producer Waratah. • Waracar is own product of Waratah. • There are some 65 Waratah cars in operation and since the acquisition only one produced under Kopex management (08/2010) • Shuttle car is powered with 2x37 KW DC traction motor • Up to 16 tones load capacity • Own Kopex development of EV propulsion is not planed. • For more information http://www.kopex.com.pl/ • http://www.kopexwaratah.com/ © Finpro Waracar 38 Company case: LeTourneau Technologies LeTourneau TechnologiesWheel Motors, Longview, Texas LeTourneau uses diesel- electric drives in its 50-Series loaders and dozers. AC generators replace gears, transmissions, and torque converters, while electric-drive motors eliminate axle components such as differentials, universal joints, and driveshafts found in mechanical drives. A major benefit is better fuel efficiency, says the company. The electric drive lets the engine operate at a nearconstant rpm, eliminating the constant acceleration and braking of massive rotating engine components associated with mechanical drives. Lowering these fuel-robbing inertial factors reduces fuel burn by up to 20 gallons/ hr, depending on model and working conditions. Savings can easily exceed $100,000 annually, according to LeTourneau. The company‘s 1,050-hp, L-950 wheel loader with a 54,000-lb payload capacity, for example, uses brushless switched-reluctance (SR) motors, high-power insulated-gate bipolar-transistor (IGBT) switches, and digital controls. The rotor has no magnets or windings; stator poles contain a winding, similar to the field of a dc motor. In terms of performance, the SR traction motor offers a virtually flat torque curve. This means high torque at low speeds to minimize stalling, plus consistent power at any speed. The result, says the company, is faster response to operator inputs, greater digging power, and better overall performance versus mechanical-drive equipment. In addition, electric drives do away with the need to shift gears, which improves cycle times and reduces operator fatigue. © Finpro 39 Company case: Liebherr • Liebherr is a group of companies, employing a workforce of 32,091 in more than 100 companies on all continents. • Company offers e.g. mobile, crawler, maritime and construction cranes. Also earthmoving and material handling equipment. • One of the leaders worldwide in material handling. • E.g. Stationary excavators are available electric as well, but with cable. • www.liebherr.com • Example: Hydraulic Excavator R 9350 Electric © Finpro 40 Company case: Manitou and MLM France • • • • • • • • • Manitou is world‘s leading producer of rough-terrain handling equipment, especially forklift-trucks. It‘s three major activity sectors are construction, agriculture and industry. The company is based in Ancenis in western France, and it has 24 subsidiaries and around 600 points of sale around the globe. Manitou‘s turnover in 2009 was 684M€ from which the part of France was 243M€. Manitou doesn‘t produce large electric working machinery at all. In addition, the company probably doesn‘t have any plans for starting to produce electric heavy machinery. However, Manitou produces small electric working machinery such as warehouse equipment (transpallets, stackers, small forklift-trucks) under their product series MANILEC. The production of MANILEC products takes place in one of the Manitou‘s subsidiary, MLM, near Paris. MLM designs, manufactures and markets both manual and electric warehousing equipment (e.g. transpallets, stackers, small forklift-trucks) under Manitou‘s product mark MANILEC as well as under their own product mark LOC. MLM‘s turnover was 16M€ in 2008. The company has around 100 employees. Most of the MLM‘s products are electric warehousing equipment for industries in all sectors in national and international markets. The product design takes place in their own R&D unit in cooperation with Manitou‘s R&D staff, in accordance with their customers‘ needs. The special expertise of MLM are manual and electric transpallets as well as stackers of all types. Most of the products are electric with 24V traction batteries. They have manual and electric transpallets, electro-manual and electric stackers, small electric forklift-trucks, electric order pickers and electric tow trucks. Additionally, the company offers used equipment to customers for renting. Practically the whole turnover comes from electric work machinery, and more specifically, from electric warehousing equipment. Company is constantly changing and developing their product range above all according to the demands of the customers. For more information see: http://www.fr.manitou.com/index.jsp?id=1291&key=S50L51R52R1260P1291&xsl=page_ contenu_filiale.xsl © Finpro 41 Company case: New Holland New Holland is a global company and a part of Fiat Group (about 20% of Fiats turnover comes Agriculture and Construction division). The acriculture division offers a large portfolio of products for farming and soil preparation. Example: New Holland NH2 Hydrogen Tractor • Fuel Cells System transforms Hydrogen into electricity that runs two motors. The tractor has zero emissions. Only a little amount of water, in the form of steam, is produced by the Fuel Cells System. • • • • • • Benefits of new system. No Noise - Better operator‘s comfort No Emissions No gears, no power losses Power delivered only as needed Limited work hours are the disadvantage of the machine • • New developments: New design and architecture constraints – intirelly new tractor design Less weight and components - Greater reliability due to fewer moving parts Replace hydraulic system and mechanical drives with electrical ones. Electrical driven implements (planters, fertilizer spreaders, etc) • • • • http://agriculture.newholland.com/uk/en/WNH/hydrogen/Pag es/HydrogenMediagallery.aspx © Finpro 42 Company case: Nissan Nissan forklift co. is a part of Nissan motor corporation and is active globally with manufacturing in Japan, Spain, Sweden and the USA. Since the manufacturing volume has increased at the individual plants, Nissan Forklift gradually increased the level of local sourcing of components. As part of the Nissan Automotive organization Nissan forklift has access to technologies developed for the automotives. Forklifts are available in LPG or Diesel powered as well as electric versions. Example: Nissan Li-ON forklifts • 3,5 ton electric powered forklift introduced on market in 2008. • In 2007, Nissan and NEC Corporation, and its subsidiary, NEC TOKIN, established a jointventure company – Automotive Energy Supply Corporation (AESC) – to focus on lithium-ion battery business opportunities. This synergy resulted in the world‘s first lithium-ion battery powered forklift, unveiled during the Logistech Show held in September 2008. Technology • AC brushless motor system (hydraulic pump & dual drive motors) Example: Nissan FCV • Development of Nissan‘s future Fuel Cell Vehicle (FCV) • Research and investigation based on Methanol Fuel Cell • http://www.nissanforklift.com/green/eco-innovation.htm • http://green.autoblog.com/2007/08/16/nissan-using-fuel-cell-fork-lifts-at-smyrna-assemblycomplex/ • http://green.autoblog.com/2009/08/26/nissan-to-deploy-methanol-fuel-cell-material-handlingequipment/ © Finpro 43 Company case: Mecalac Ahlmann • • The MECALAC AHLMANN Group offers a wide range of innovative equipment and services for today‘s urban construction sites. Small and innovative company, about 400 employees, manufacturing facilities are located in France and Germany. Example: Mecalac 12MTX Hybrid • • • • The 68-hp (51 kW) rated 4-cylinder B3.3 engine drives an electrical generator and lithium-ion battery system to achieve 25 percent lower fuel consumption with reduced CO2 emissions and quieter operation. The 9-ton (8.1 t) 12MTX Hybrid has the ability to operate as excavator, loader, materials handler and other functions with a quick change of tool attachments. Based on the compact and agile 12MTX, the hybrid version is the latest machine from the Mecalac Ahlmann Group, who specialize in equipment ideally suited for city center construction sites with limited operating space. The B3.3 engine incorporated within the diesel-electric system operates at an engine rpm speed optimized for fuel efficiency. The 68-hp mechanical power of the engine output is rated to match the average power requirement of the machine. When less than 68 hp is needed, the batteries are charged; when more than 68 hp is needed, the electric motor provides additional power up to 99 hp (74 kW). A power loop electronic control system ensures a seamless power adjustment between diesel engine and electric motor. www.mecalac.com © Finpro 44 Company case: Rocla In its 65 years of operations, Rocla has evolved from a small family owned company into a world class materials handling manufacturer listed in the Helsinki Stock Exchange. Company was bought in 2008 by Mitsubishi Caterpillar forklift corporation. Example: AGV - Automated Guided Vehicles An automated guided vehicle (AGV) is an automated electric truck that performs driverless material handling operations between load handling positions. In 1983 the first delivery of AGV system • Fully automated, personnel free logistic system • Main applications in paper, packaging, food, automotive industry • Technology • • Electro powered stock house forklifts (carriages) Guiding system secure the full automatic and collision free movement • http://www.rocla.com/productlist.asp?Section=477 © Finpro 45 Company case: Sandia Sandia National Laboratories has developed science-based technologies Since 1949. Sandia is a government-owned/contractor operated (GOCO) facility. Sandia employs 8,200 people in the USA. Example: Fuel Cell powered deep mine locomotive • A public/private consortium that included Sandia developed a 4-ton hydrogen fuel-cell-powered mining locomotive, which was successfully tested in early 2002. • In September 2002, the vehicle became the first hydrogen fuel-cell-powered locomotive to be operated underground, successfully pulling five loaded cars weighing 20 tons at Val d'Or, a former metal mine in Quebec maintained for mining experiments. Earlier that year, the mining industry gave the locomotive a "best of show" award at the Canada Mining Expo. • The project, which involved nearly a dozen partners, was largely funded by the U.S. Department of Energy. • Hydrogen storage systems are also developed by Sandia • • https://share.sandia.gov/8700/projects/content.php?cid=178 http://www.sandia.gov/hydrogen//research/engineeredSystems/mineVehicle.html © Finpro 46 Company case: Same Deutz-Fahr • • one of the world‘s main manufacturers of tractors, combine harvesters, farm machinery and engines Focused on developing innovative solutions for high efficiency vehicles, mostly agricultural tractors Example: • Hybrid Electric solutions are under development on those vehicles that have non constant power duty cycle. Hybrid‘s do not offer benefits on a constant power duty cycle, since diesel engine can be optimized to maximum performance. Electric (Hybrid) solutions are therefore effecting the complete design of the vehicle, the approach requires a 360° open layout solution. • For more information see: http://www.samedeutz-fahr.com © Finpro 47 Company case: Sennebogen • • • • Since it was founded in 1952, the family company SENNEBOGEN has been developing and producing cranes, telescopic cranes, special machinery, materials loaders and hydraulic earth moving machinery. Almost all stationary and crawler models are available electric as well, but always with cable, no battery. Example: The new SENNEBOGEN 825 Crawler D-Series Electro combines all the benefits of the well-established SENNEBOGEN D series and represents the large number of machines from the Green Line supplied with electric motor. For years, SENNEBOGEN has been supplying all Green Line machines to meet customer specifications, including with electric motor, and boasts a leading position on the market. This extremely economical and environmentally friendly motor offers a whole host of advantages compared with a diesel engine. Refueling time is eliminated, maintenance requirements are significantly lower than with comparable diesel machines and the operating life of the components is greatly increased. There is also the benefit of zero emissions with constant 100 % performance – all extremely persuasive arguments which are winning over ever more customers. www.sennebogen.com/ © Finpro 48 Company case: STILL STILL is a supplier of a complete range of forklift trucks, platform trucks, tractors, plus the latest warehouse handling equipment and forward looking services established in 1920. Company employs some 600 persons. Example: new RX 70 Hybrid • STILL Hybrid Trucks in series production • The new RX 70 Hybrid takes the next step on the way to low energy consumption and low CO2 emission. The truck has been devised on the basis of the successful RX 70 diesel truck and is the first hybrid lift truck made in serial production. • With the new RX 70 Hybrid STILL will test the market acceptance in field tests with customers. Technology • The new RX 70 is equipped with two energy saving systems. • Beside the diesel tank, the truck is equipped with SuperCaps which are installed on the counter weight. These twin layer capacitors are charged with the energy released during braking. When accelerating, this energy from the capacitors is used to give an additional boost to move the truck forward. • In addition the diesel engine generates electric energy for the drive motor. All systems are combined by the power electrics which also controls charging and discharging the additional energy storage. Example: Blue-Q • The intelligent auto pilot for economy and ecologic responsibility • Blue-Q efficiency mode can be activated when using the STILL machiner: An intelligent adjustment of the motor characteristics saves energy just there where it is not needed for the work in process • 10-20% savings of energy targeted • • http://www.still.co.uk/hybrid-trucks-series-production.0.0.html http://www.still.co.uk/intelligent-auto-pilot-blue-q.0.0.html © Finpro 49 Company case: Toyota MH Toyota Industrial equipment company serves the market with Material Handling equipment since 1956. Company is one of the a global market leaders. Example: Toyota Material Handling Forklift • 8 series 4 wheel forklift up to 3,5 t. • Fully electric solution. • Source of power is Li-ION battery. • • • • • • Technology AC (Alternating Current) drive system It features an electrical system AC lift motor features fully variable lift/lower control for fast, precise pallet retrieval or positioning. AC drive motor offers quicker acceleration, higher top speeds and smoother direction changes System of Active Stability™ (SAS) movements Power keep function allows the 8-Series' AC motors continue to perform at productive levels even when the battery charge is low. • http://www.toyotaforklift.com/products/lift_trucks/ElectricMotorRider/4Wheel8Srs.aspx © Finpro 50 Volvo Construction • • Volvo CE‘s products and services are offered in more than 125 countries through proprietary or independent dealerships. Product range includes wheeled and crawler excavators (diggers), articulated haulers (dumpers, dump trucks), scraper haulers, wheel loaders, pipe layers, demolition equipment, waste handlers, motor graders, pavers, compactors, milling equipment, tack distributors, road wideners, material transfer vehicles and a range of compact equipment such as mini loaders, mini excavators, backhoe loaders and skid steer loaders. Example: Volvo Construction Equipment-Hybrid loader - Asheville, N.C., • Volvo is developing the L220F Hybrid wheel loader that company officials say will offer more power, better performance, and the potential to reduce fuel consumption by up to 10%, compared with current versions. This not only reduces fuel costs but also provides significant environmental benefits — such as lower CO2 emissions. • Hybrid concept was presented already in 2008 ConExpo in Las Vegas and production of the hybrid wheel loaders and the L220F model was expected during 2009 and deliveries planned for 2010. Technology: • Volvo‘s design is a parallel-hybrid system. Both an electric motor and the diesel engine connect to the mechanical transmission and propel the vehicle. (In a series-hybrid design, on the other hand, the diesel engine does not connect to the driveline but instead powers an electric generator that feeds electricity to drive motors.) • The heart of the L220F Hybrid is an electric motor called an integrated starter alternator motor (I-SAM). Fitted between the engine and transmission, the I-SAM is coupled with a lithium-ion battery with a several hundred watt capacity. © Finpro 51 Examples of present or potential (H)EV machinery producers Examples– Agriculture 1/2 Company AGCO corporation Deutz http://www.deutzamericas.co m/engines/hybriddrive.htm AGCO corporation Fendt www.agcocorp.com/products Key markets http://www.masseyferguson.com /delta/ AGCO corporation Caterpillar - Challenger www.agcocorp.com/products www.cat.com AGCO corporation Valtra www.agcocorp.com/products www.valtra.fi EV Technology / General technology trends Comments Germany, Diesel engine, Europe, Agro Machinery + Global equipment Harvesters, Tractors etc. Deutz has e.g. DEUTZ HYBRID DRIVE solutions / DVERT (Deutz Variable Emision Reductions Technology) Germany, Europe, Global Agro Machinery + equipment Harvesters, Tractors etc. No public info about EV development/ SCR Catalyzer New thrasher system in Hybrid(AdBlue) Mähdrescher 9460 X presented in 2009 and available in 2011. (powered by Agco Sisu 7.cylinder engine) UK, Europe, US, Latin America Agro Machinery + No public info about EV development/ equipment New thrasher system in MF 9280 Delta Harvesters, Tractors, ‗hybrid‘ combine presented in 2010 handling devices etc. US, Europe, Global Heavy agro machinery. No public info about EV development/ New steering and performance monitoring system introduced in C-series tractors. Finland, Europe, Latin America, Global Agro Machinery + equipment Tractors etc. No public info about EV development/ Valtra S with steer-by-wire TwinTrac presented 11/2009 www.fendt.com AGCO corporation Massey-Fergusson Key Products/ Solutions Key Clients © Finpro Other development natural fuels,e- fuel management, SCR Catalyzer Has a second steering wheel in rear of cabin for reverse drive 53 Examples – Agriculture 2/2 Company Key markets Key Products/ Solutions Key Clients AGCO corporation Global, Europe, USA Produser of diesel engines 4th generation of diesel engine for agriculture, power Engines with SCR (Selective Catalytic generators and marine Reduction) Europe, global Technology leader in Agro Machinery + equipment Harvesters, Tractors No public info about EV development/ Harvester Tucano with hybrid thrasher Telematic steering system guided by laser Global, US, Europe Technology leader in Agro Machinery + equipment Harvesters, Tractors, gardening equipment A lot of electrification research and development. Hybrid and electric solutions in light machines (e.g. green movers). Fuel efficiency due to e-control of engine. Hybrid E-cut 8000 Grass cutter powered by e-motor 7030 E Premium tractors feature integrated electrical distribution US, Europe Global Agro Machinery + equipment Harvesters, Tractors etc. Construction machinery Hydrogen powered tractor with fuel cell in concept phase R&D common with Fiat, CNH owns Steyer, Kobelco Sisu Power http://www.agcosisupower.com/produc ts/agco_sisu_power_engines/ Claas – Renault www.claas.de John Deere http://www.deere.com/en_US/Prod uctCatalog/GT/series/gt_ecut_hybr id_3whl_series.html Case - New Holland (CNH) http://www.caseih.com/ Doppstadt www.doppstadt.com Germany, Stationary and mobile Europe machines for waste management EV Technology / General technology trends Comments Most products are available in different classes with both diesel engines or electric motors. Japan, Tractors lower and middle No public info about EV development/ Asia, US class, Construction http://www.kubota.com/product/Group machinery Tractors.aspx Kubota © Finpro 54 Examples – Forestry Company John Deere Forestry Key markets Global http://www.deere.com/en_US/cfd /forestry/deere_forestry/homepa ge.html Key Products/ Solutions Key Clients Technology leader, Wide specter of solution, harvesters, forwarders, heavy machinery Finland, Global technology leader Europe, Global Wide specter of solution, http://www.ponsse.com/english/g harvesters roup/CTL/index.php Ponsse Sampo – Rosenlew http://www.samporosenlew.fi/en/tuotteet_en/metsa koneet_en/harvesterit_yleista_en .html Valmet Komatsu Forest Finland, Europe http://forestpro.cat.com/cda/layo ut?m=64873&x=7 Elforest www.el-forest.se JD announced aim in EV development 06/2009/ Innovative E-serie harvester equipped with rotating cabin 06/2008, Comments E-control system TimberMatic H-09 measuring No public info about EV development/ Cut to length strategy Harvester Ergo 8x8, Multi-steering system, harvesting head for eucalyptus No public info about EV development/ Sweden, Europe, US, Global Wide specter of solution, No public info about EV development/ harvesters, heavy Evolved system of customer Support machinery as simulators, schooling and praxis Forwarders. Development leader on field of logging Europe, US, Global skidders, forwarders heavy machinery No public info about EV development/ B-series Cat® 559B. Knuckleboom presented 02/2009 Increase Fuel economy with new hydraulic power system Sweden, Europe El-Forest forwarder The El-forest forwarder is the first hybrid- electric driven forwarder in the world. First machine delivered in 2009 In 2007 Volvo Technology Transfer AB invested in Elforest AB. http://www.komatsuforest.com/ Caterpillar Basic specter of solution, Small and compact harvesters EV Technology / General technology trends © Finpro 55 Examples – Mining 1/2 Company Key markets Sandvik Mining Finland, Global Machinery and equipment for Mining (both deep and open) Tunneling Construction LHD 14 t Electro powered deep mining Target industries are loader with 3phase drive motor and up very suitable for to 400 m cable reeling system electric applications. 1Q/2010 Sweden, Global Deep mining equipment , open pit, cement solution etc. Kiruna electric truck for deep mining since 1980s developted with GIA Surface mining products like loaders and dozers Diesel- electric drives in loaders and dozers powers electric wheel motors. http://www.miningandconstructi on.sandvik.com/ ABB Mining http://www.abb.com/industries/ LeTourneau http://www.letourneau-inc.com Sandia USA, Americas, World Key Products/ Solutions Key Clients USA, Canada Deep mining http://www.joy.com/Joy/Haulag e-Systems/Battery-HaulageOptions.htm US, Global Comments Fuel Cell powered deep mine locomotive http://www.sandia.gov/hydroge n/research/engineeredSystems /mineVehicle.html Joy mining company EV Technology / General technology trends Market leader in haulage systems Machinery and equipment for Deep Mining JOY battery hauler 20 t load vehicle, use AC-Variable Frequency Drive Control System (AC-VFD) Hydraulic battery exchange system JOY battery haulers © Finpro 56 Examples – Mining 2 /2 Company Key markets Key Products/ Solutions Key Clients Finland, global Very wide specter of solutions underground mining and http://www.normet.fi/processes_pr tunneling. Concrete spraying, oducts lifting Normet oy Bucyrus USA, Global http://www.bucyrus.com/mining -equipment.aspx Very wide specter of solutions for surface mining , Long wall mining Sweden, Very wide specter of solutions Europe, Global underground mining, tunneling, http://pol.atlascopco.com/SGSit rock drilling and construction e/default_prod.asp Atlas Copco EV Technology / General technology trends Comments No public info about EV development/ EV technology is used for propulsion of on board aggregates EV – used in quasi/stationary solutions like shovels in electric version Electrical Scooptram EST2D small loader with cable reeling system/ Wide usage of EV technology in processing and stationary solutions. Self operating eqp. Distance steering Poland, Russia, Europe, India Wide specter of solutions for surface and deep mining No public info about EV development/ EV – used in quasi -stationary solutions like excavators, haulers. http://www.famur.com.pl/page/index/77 Poland, Russia, Europe, India Wide specter of solutions for surface, deep mining, transportation No public info about EV development/ E-mining – control EV – used in quasi -stationary and diagnostic solutions system Terex USA, Global Very wide specter of solutions for surface mining EV – used in quasi/stationary solutions like shovels in electric version German, Global SCHOPF produces specialist vehicles for the mining and aviation industries F110 ―electric‖ aircraft tow tractor ZZM-KOPEX http://www.kopexfamago.eu/?pid=ho me&language=en FAMUR http://www.terex.com/main.php ?obj=category&action=BROWS E&nav=prod SCHOPF http://schopfgse.com/news/news2.php © Finpro Also SCHOPF ROFAN ZH 5 - a fast, flexible freight tractor with PowerHybrid drive 57 Examples – Construction 1/2 Company Liebherr http://www.liebherr.com/me/defa ult_me.asp Volvo – construction http://www.volvo.com/constructio nequipment/na/enus/products/pavers/introduction. htm Key markets Key Products/ Solutions Key Clients EV Technology / General technology trends Comments Germany, Technology leader, Europe, Construction, Cranes, Global Earthmoving , Mining, Demolition, Heavy transport EV solutions used in quasi - stationary machines Sweden, Europe, Global Hybrid wheel loader L220, presented 2008 Machines are BioFuel ECR305C Short swing excavator, Electric ready. Presented heating systems for paving machines concepts include excavator and wheel loader. Technology leader Specialized on landscape construction Zeppelin – Caterpillar Germany, Technology leader, Europe US, Very wide specter of solutions http://www.zeppelinGlobal for construction, Earthmoving cat.de/D/lieferprogramm/01grab en/0771939de.html D7E dozer with e-drive, replacing mechanical gearbox. In development: heavy load e-truck. US, Global Very wide specter of solutions for construction, Earthmoving , http://www.terex.com/main.php? Mat. Handling, surface mining, obj=category&action=BROWSE Military &nav=prod Terex Telelect HyPower Hybrid System use for utility vehicles. They stay still while working Terex © Finpro Mining truck trolley version D7E is a diesel electric solution 58 Examples – Construction 2/2 Company Key markets Key Products/ Solutions Key Clients Japan, Very wide specter of solutions Asia, global for construction, Earthmoving , http://www.hitachi-cMaterial Handling, m.com/global/company/csr/envir onment/research/loader.html Hitachi Hyundai http://www.hyundai-ce.com/ South Equipment for construction, Korea, earthmoving, industrial vehicles Asia, global EV Technology / General technology trends Diesel-electric trucks for mines recuperates the braking power. Hybrid wheel loaders L130 launched 11/2008. Hyundai hybrid excavator 22 tones hybrid excavator prototype will be putted into full production in 2011. Japan , Very wide specter of solutions US, Global for construction, Earthmoving http://www.komatsu.com/Compa nyInfo/press/2008051315113604 588.html Komatsu is going to launch worldwide sales of HB205 and HB215LC hybrid hydraulic excavators, initially in Japan South Equipment for construction, Korea, earthmoving, industrial vehicles http://www.doosan.com/doosa Asia, global ninfracore Doosan hybrid excavator Komatsu Doosan Mecalac Ahlmann http://www.mecalac.com/en/Pr oducts/ DANA http://www.dana.com France, Europe Light and medium construction equipment USA, Europe, Global System supplier for construction, Spicer TE-15HX electric parallel hybrid automotive and truck industry © Finpro Comments Expected launch on American market in 2012 Mecalac 12MTX Hybrid Inovation in area of Fuel cells. 59 Examples - Material Handling 1/2 Company Key markets Key Products/ Solutions Key Clients Germany, Technology leader, Europe, Global Wide specter of logistic http://www.jungheinrich.de/de/com/index solution, Forklifts -de/produkte/logistiksysteme.htm Wide service offer and planning Jungheinrich Linde Material handling http://www.lindemh.com/en/main_page/puremotion/pure motion_1.jsp Cargotec http://www.cargotec.com/cms/cargocms 20.nsf/Documents/27CDB2918B942D05 C2256FDB003E53DF?openDocument&l ang=1& Rocla http://www.rocla.fi/productlist.asp?Sectio n=477 Germany, Wide specter of logistic Europe, Global solution, Forklifts EV Technology & technology trends Comments EV battery technology used for forklifts E.g. electric counterbalance trucks and batteries and chargers for these Electric forklifts, Natural gas as interim solution, but aiming at hydrogen powered fuelcells, on-board Chargers, hydrostatic drive and E-Management Linde Pure Motion is their flagship and concept for environmental production and products Finland, Europe Kalmar container and heavy material handling and HIAB load handling solutions, etc. Kalmar all-electric RTG‘s, E-One –concept for HIAB forklifts electric or energy savings and hybrid version available in greener products addition to diesels, on heavier equipment focus on fuel efficiency Finland, Europe Technology leader, Specter of logistic solution, Forklifts Electric forklifts since 1960‘s Automatic guided forklifts, EVgenerally used for inhouse solution France, Technology leader, EV used in small to medium Europe, Global Heavy MH machines, Forklifts class Forklifts http://www.gp.manitou.com/en/index.htm l Manitou BF Toyota Material Handling http://www.globaltoyotaforklifts.com/products/index.html Japan, Asia, US, Global Wide specter of logistic solution, Forklifts © Finpro EV used in small Forklifts SAS - System of Active Stability AC2 power management, Powerdrive with CAN –Bus tech. 60 Examples – Material Handling 2/2 Company Key markets Key Products/ Solutions Key Clients Germany, Technology leader, Europe, Global Specter of logistic solution, http://www.zeppelinForklifts used.de/D/gabelstapler/presse/Neue_ US, Europe, Global Technology leader, Specter of logistic solution, Forklifts US, Europe, Global Electric burden, light person/load carrier Electric utility carts and electric utility E.g. Light e- truck ET-150_74AC_r1 vehicles Japan, USA, global Forklifts Nissan Li-ON forklifts, 3,5 tone electric powered forklift E-Stapler_80V.html http://www.crown.com/usa/products/tec hnovation/performance.html Taylor-Dunn http://www.taylordunn.com/vehicle_search.aspx?mo de=base&type=utility_vehicles Nissan Forlift http://www.nissanforklift.com/gr een/eco-innovation.htm Germany, Forklifts, platform trucks and Europe, Global tractors http://www.still.co.uk/product s-uk.0.0.html STILL Sennebogen www.sennebogen.com/ Comments EV- technology generally used for 80V Forklifts indoor products and forklifts. Several J2.2-3.5XN series models. introduced on German market 01/2010 Access 1 2 3® Electric forklifts and stockpickers, also gas and LPG powered solutions QuickPick™ Mono-Mast (Hamech Brand name) Zeppelin Crown EV Technology & technology trends Germany, Europe Nissan FCV Development of Nissan‘s future Fuel Cell Vehicle (FCV) RX 70 Hybrid Trucks in series production Cranes, Bulk material, scrap SENNEBOGEN 825 Crawler crawler for quasi stationary use. D-Series Electro © Finpro 61 Examples – Logistics Company Mercedes-Benz http://www.mercedesbenz.de/content/germany/mpc/mpc_ germany_website/de/home_mpc/truc k_home/home/trucks.flash.html Eaton http://www.eaton.com/EatonCom/Pr oductsServices/Hybrid/SystemsOver view/HybridElectric/index.htm DAF http://www.daf.com/EN/Products/Mo del-Range/Pages/Model-Range.aspx MAN http://manag.manmit.com/MAN/de/Unternehmen/Prod ukte_und_Maerkte/Unternehmensbe reiche/Nutzfahrzeuge/ Mitsubishi http://www.mitfuso.com/ Volvo http://www.volvotrucks.com/TRUCK S/GLOBAL/ENGB/TRUCKS/Pages/trucks.aspx Renault http://mediacenter.renaulttrucks.com/site//bases/default/index. asp Key markets Germany, Europe, Global Key Products/ Solutions Key Clients Technology leader, Wide specter of solution Trucks -> light duty vehicle, Tractors - Unimog EV Technology & technology trends Comments Atego BlueTec Hybrid medium Development topics generally: recuperation units and flywheel duty truck. solutions for saving energy by braking. USA, Americas, Global System supplier for automotive Hybrid power system for truck and truck industry Netherland, Europe, Global (part of Paccar) Trucks (diesel) EEV (Enhanced Environmentally SCR/ AdBlue friendly Vehicle) engine for innercity distribution fuel efficiency, etc.. Germany, Europe Global Wide spectrum of solution Trucks -> light duty vehicle, MAN Disel and Turbo Green technology fuel efficiency and use of biofuels Japan, Asia, Global (part of Daimler) Wide spectrum of solution Trucks -> light duty vehicle, Hybrid solution in investigation Sweden, Europe, US, Global Technology leader, Wide spectrum of solution Trucks ->LDV Only successful European producer Ii US Volvo has developed a hybrid Concept Truck 2020 drivetrain system called I-SAM http://www.youtube.com/watch?v and is participating in new type of =SMcNq36IhY4 battery development. -Effpower France, Europe, Global Wide spectrum of solutions Trucks -> light duty vehicle, © Finpro Optifuel solutions: fuel efficiency and emission reductions. In IAA 2008, MAN presented 2 hybrid drive concepts: municipal bus with serial hybrid drive and ultracaps to store energy, as well as a TGL model distribution truck with parallel hybrid drive In 2007, Hybrid innovatory urban concept vehicle exploiting a parallel hybrid technology 62