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Fronius Selectiva 8kW & 16kW
1. New products: Selectiva battery charging systems – 8 &
16 kW power range
Fronius International GmbH
Battery Charging Systems division
Froniusplatz 1
A-4600 Wels
3. 3
Energy efficiency from the ground conveyor
manufacturer
/ Focus on reduction of vehicle power consumption, e.g. energy recovery when braking or
lowering the mast.
/ Stacker sales personnel are primarily concerned with just selling the ground conveyor;
battery and battery charging systems are of secondary importance
/ Lack of expertise in battery charging technologies means that energy efficiency is
generally not thought of in terms of the entire three-part system
/ Customer demands for energy efficient solutions have only recently come to the fore as
many customers do not know how much power their ground conveyors use
4. 4
Annual power consumption of a lift truck fleet
/ 100 lift trucks
/ Single-shift operation
/ Battery 24 V, 440 Ah
approx. 300,000 kWh
per year
5. 5
Annual power consumption of an electric stacker fleet
/ 100 electric stackers
/ Single-shift operation
/ Battery 80 V, 620 Ah
approx. 1,450,000 kWh per year
10. 50 Hz transformer technology
10
Advantage:
/ Reasonable purchase price
/ Low failure rate
Disadvantage:
/ Old technology with poor energy
efficiency
/ Higher battery warming
/ Not so safe
I / U
0% 25% 50% 75% 100% 120%
State of charge
W o W a
11. 11
HF technology
I / U
0% 25% 50% 75% 100% 120%
State of charge
I U I a
Advantage:
/ Energy efficient
/ Longer battery
service life
Disadvantage:
/ Higher failure rate
12. 12
Fronius Active Inverter Technology
I / U
0% 25% 50% 75% 100% 115%
State of charge
I U I a
Advantages:
/ Energy efficient
/ dU/dt – Lower
battery warming
due to modified
charging in the
recharging phase
/ Industrial quality
Disadvantages:
/ Higher purchase
price
dt
dU
13. 13
The charging process of these technologies
/ What all battery charging technologies have in common - whether 50 Hz transformer
technology, HF technology or earlier Active Inverter Technology products - is that their
charging processes use prepared charging characteristics that are “imposed” on the
battery. This involves executing a defined charging program without having to take
account of the current charge level of the battery.
/ Fronius stood apart from the competition with the earlier Active Inverter Technology - the
recharging phase is entered in such a way that battery overcharging is kept as low as
possible (dU/dt).
/ The charging process as a formula:
U = I x R
-> I (current) is predetermined during this charging process
15. 15
The development goal
/ The new generation of battery charging systems was developed with a focus on process
technology.
/ Alongside a revolutionary new battery charging process, the new generation boasts a
plethora of improvements over earlier products. As a result, the number of beneficial
properties has been increased and technical deficiencies in the face of competitor
products have been corrected.
18. 18
Until now we have only
considered the battery condition
during the recharging phase.
This is now the case throughout
the entire battery charging
process.
19. 19
The Ri characteristic
Competitor 50 Hz & HF as well as earlier Fronius:
U = Ix R
-> I (current) is predetermined during this charging process
New Fronius:
U = I x R
-> U (voltage) is regulated, I (current) responds accordingly
20. 20
Or in other words:
From now on, every single battery
charging process uses an
individual charging characteristic
based on the current condition of
the battery.
21. 21
Common “standard charging process” for traction batteries
0% 25% 50% 75% 100% 120%
I / U
State of charge
I U I a
23. 23
0% 25% 50% 75% 100% 107%
RiI / U
State of charge
0% 25% 50% 75% 100%
RiI / U
State of charge
New battery
Modified battery
“Ri charging process” - new and modified batteries
24. Applied
energy
(100% AC)
Conversion from AC to DC
(electrical process in 50 Hz
transformer technology, HF or
AIT) - 7% power loss
Energy available
for
charging
Energy available
for ground
conveyor
Device efficiency 93% Charging efficiency 90%
Process efficiency (= overall efficiency) 84% with Ri
Technology Device
efficiency
Charging
efficiency
Process
efficiency
50 Hz 80% 70% 56%
HF 90% 75% 68%
Fronius AIT 92% 80% 74%
Fronius AIT with Ri 93% 90% 84%
Characteristic-based battery charging -
the better the characteristic, the more
energy the battery can store
(electrochemical process)
25. 16% extra energy
is required by
Fronius AIT with Ri
to fully charge the
battery
Process efficiency
(overall efficiency) 84% of
Fronius AIT with Ri
Technology Device
efficiency
Charging
efficiency
Process
efficiency
Energy loss during
100% battery charge
50 Hz 80% 70% 56% 44%
HF 90% 75% 68% 32%
Fronius AIT 92% 80% 74% 26%
Fronius AIT with Ri 93% 90% 84% 16%
Battery must be fully charged
(100%) to ensure stacker
availability
26. 26
Result
/ Lowest energy consumption from the socket to the stacker
/ Lowest battery warming during the charging process extends battery service life
/ Lower battery warming results in less battery contamination and lower water consumption
29. 29
Hardware
/ Weight: Selectiva 8 kW at c. 18.5 kg remains the same, Selectiva 16 kW at approx. 30 kg
is 10 kg lighter
/ Dimensions: Selectiva 8 kW about the same, 16 kW significantly smaller
/ New design to implement service concept
/ USB interface
30. 30
Software
/ Single-cell charging possible due to adjustable number of cells
/ Refresh characteristic
/ Time-delayed charging
/ Approx. 15 more characteristics as standard, e.g. for gel batteries
/ Preparation for charging of lithium-ion batteries already envisaged
31. 31
Quality
/ Industrial quality
/ Household standard
/ New ventilation concept
/ Real-time clock and calendar function
/ IP 21 protection class, optional upgrade to IP 23.
32. 32
Information
/ Power LED: status of battery charger easily discernible from a distance
/ Large, high resolution display: display of several charging parameters possible
/ Easy software updates using USB stick
/ Automatic data logging: the 20 most recent charges are saved in detail, key figures are
saved for the last 1500 charges (battery service life)
33. 33
Safety
/ Error message. A service number can also be shown alongside the state code. Text can
be allocated to warnings. Previously just state code only with no additional information.
/ Reverse polarity protection now as standard, used to be optional
/ Mains voltage monitor
/ External start/stop
/ Safety cut-out
/ Voltage-free charging plug
/ Cumulative error
34. 34
Service
/ First Fronius battery charger for which components can be replaced on-site.
/ Servicing can be provided by partners
/ Data protection. Even when faulty components are replaced on-site, all relevant data
remains safely stored in the device.
35. 35
Options
/ All options (excluding EUW) are now available as upgrades
/ Integral EUW pump
/ Optional PC board
/ Temperature-controlled charging
/ External start/stop
/ Remote control
/ Wall and floor bracket
/ Network interface
/
(late 2013)
38. 38
February 2013
/ Premiere at LogiMAT
March 2013
/ Start of production
- Selectiva 8 kW 2014
/ Planned: successor Selectiva 3 kW
2016
/ Planned:
successor Selectiva 1 kW
May 2013
/ Start of production - Selectiva 16
kW
ROADMAP
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