Research Project Summary Information
Electric Double Layer Capacitor Power Module for Raymond Corporation (ST10820-1)
Many forklift trucks are powered by electrical energy provided by banks of lead acid storage batteries, which may be recharged after their useful energy has been extracted. Often as these rechargeable batteries discharge, a “voltage droop” occurs, causing sluggish operation of the forklift truck under load or acceleration. Most often, this occurs around 6 hours into a shift, requiring an additional recharge per shift, whereby reducing the life of the battery.
The Contractor, Renewable Energy Development, Inc. (REDI), has developed a solution to this “voltage droop” problem. By placing electric double layer capacitors (EDLCs) in parallel with the lead acid batteries, more of the energy stored in the batteries can be accessed, while also allowing the battery to operate in its “comfort zone,” even under high load conditions. This also allows the battery packs to operate at a lower temperature which helps prolong their life. The EDLCs supplement the energy from the batteries to provide the additional current required under a momentary load increase.
This project has the target of increasing the duration of the battery pack from 6 hours to 8 hours without noticeable voltage droop and increase the cycle life of the battery pack, though incorporation of the EDLC power module.
Preliminary testing of this EDLC power module has shown an increase in battery life, allowing forklift truck operation over a full 8-hour shift without the need for recharging. Further design and development under this contract will transition the concept to product. Electronics interfacing design and testing will be performed to ensure compatibility of the EDLCs with the other electronics that exist on the forklift. A new housing will be developed for the module such that it will allow for retrofits into existing forklifts, in addition to installation in new ones.
Potential benefits include increased battery cycle life, energy savings from increased efficiency of battery use, reduced battery landfill waste, and reduced battery replacement expense.
18 Stadium Circle
Oneonta, NY 13820
NYSERDA Contact Information
R&D -Transport & Power Systems