Increasing Forklift Capability without increasing ICE size

Background

A forklift OEM wants to increase the largest forklift they offer by 20%. The OEM wants to stay with the same diesel engine supplier; however, they are already using the largest ICE offered. The OEM wants to know if it makes sense to increase the power necessary with a hybrid before considering a different ICE supplier.

Project Objective

Determine if a hybrid powertrain makes TCO and initial cost sense. Optimizing for TCO, determine what battery size should be used. Determine the initial cost difference between a hybrid and increased ICE only.

ePOP Approach

Increase the application function power cycles by 20% over the existing model. Limit the ICE component size to the largest from the preferred supplier. Consider multiple hybrid configurations and technologies.

ePOP Outcome Delivered

Adding an electric motor parallel to the existing ICE configuration is possible at a 7% increase in initial cost while maintaining similar TCO. A non-plugin series hybrid configuration with eAxle could reduce 7 year TCO by 15% with a 7% increase in initial cost. Optimum ICE size is actually smaller than the existing large ICE. Optiman battery size is 16kWh. A plugin version would reduce TCO another 2%.