Reduction of emissions and fuel consumption
In light of the stricter exhaust emissions standards, LMH and STILL undertook significant projects to reduce emissions (see in the sections Regulatory situation and Sustainability).
For example, LMH put new engines into its counterbalance trucks in the 2.5-5 tonne weight category and fitted them with a particulate filter system as standard in order to meet the European Stage IIIB limits for diesel-powered forklift trucks with an output of 37kW or higher, which came into force in January 2013. Trucks in the Linde EVO series produce emissions at a far lower level than permitted limits and achieve double-digit percentage reductions in fuel consumption. Series production will begin in early 2013. Another major project at Linde was the development to production readiness of a new reach truck. This truck also offers lower fuel consumption and a variety of attractive new product features. In addition, LMH expanded the range of model variants in its electric forklift truck series in the 2-5 tonne weight category.
A focus of development activities at STILL was the new reach truck, which is based on the Group's platform concept. Two diesel counterbalance trucks in the 4-5 and 6-8 tonne weight category are also being developed. They will go into series production in 2013 and will also comply with the new emissions standards.
Drive technology
Development of new drive technologies centred on powerful lithium-ion batteries for electric and hybrid trucks. Various sizes of battery for hand pallet trucks and towing vehicles were refined at the development centre in Châtellerault, France. LMH and STILL expect to offer the first trucks fitted with lithium-ion batteries at the end of 2013. They store considerably more energy and can be charged faster than lead-acid batteries.
In addition, LMH and STILL are also pushing forward with the development of lithium-ion batteries for counterbalance trucks in higher weight categories. Another project, which LMH is working on with a strategic partner, is concerned with developing high-performance booster batteries for hybrid trucks. In 2010 STILL was the first manufacturer worldwide to go into series production with a hybrid truck. This truck combines a drive system based on an internal combustion engine with a breaking-energy recuperation system from an electric truck, enabling it to achieve very low emissions values. Customer testing of the trucks provided feedback for product development. In November 2012 the hybrid truck won the new Federal Ecodesign Award from the Federal Ministry for the Environment, Nature Conservation and Nuclear Safety and the Federal Environment Agency.
In 2012 LMH's Electronic Systems & Drives (ES&D) unit teamed up with a strategic partner to develop the Rotrac E2, an electric trolley for pulling very heavy loads. It can be used to shunt rail vehicles, for example. A prototype of a container loader with an eco-friendly drive concept for use at airports has been undergoing field-testing since mid-2012.
KION is also participating in a government-sponsored research project (E-LOG-Biofleet) to improve handling and environmental friendliness using a fleet of industrial trucks with a fuel-cell hybrid solution. As part of the project, Linde equipped a fleet of ten trucks, which a customer has been putting through field tests since the end of 2012. The strategic partner for this project is a manufacturer of battery charging systems. STILL continued its longstanding international fuel cell activities for industrial trucks in 2012, putting an additional six trucks into operation for two clients.
Workplace safety and ergonomics
The safety features of the industrial trucks continued to be refined in 2012. The new models in the Linde EVO series are the world's first diesel trucks with a 'curve assist' system fitted as standard. This system adjusts cornering speed depending on the steering angle. An automatic parking brake has been developed for electric trucks, thereby improving convenience and safety. STILL developed a new restraint system, netProtect, which operates automatically so that the driver does not have to fasten or undo the seatbelt manually.
The KION companies are also working on further reducing human vibration and other vibrations, including by improving the seats and cushioning.
Region-specific and customer-specific design
In 2012, KION's R&D centre in Xiamen focused on adapting truck concepts to meet the specific requirements of customers in China and other emerging markets. A basic, low-cost variant of a new counterbalance truck, which has a drive unit with a torque converter, was almost ready for series production at the end of 2012. LMH will use a platform concept to offer three models with different drive systems in different price categories. Progress was also made with three types of warehouse truck and a smaller towing vehicle that can pull loads of up to 2 tonnes. It will be marketed in China and elsewhere rounding out the product range at the lower end.
In 2012 customisation of industrial trucks to meet customer requirements featured more heavily in R&D activities than in previous years. The modular concept is intended to help KION to fulfil customers' requirements with even greater flexibility and speed in future.
Networking
The KION Group is working on refining material-flow management systems (MMSs) to meet the growing demand for automated solutions. At the Hannover trade fair in April 2012, STILL showcased a prototype of an autonomous reach truck that can independently navigate through a warehouse and respond to changes in the environment. The prototype was built in cooperation with partners as part of a project sponsored by the Federal Ministry of Economics and Technology.
The order-picker truck that was launched in 2012 can also navigate independently. The STILL PalletShuttle was launched in 2012: this semi-automatic storage and retrieval system can be integrated with STILL's MMS. Presented at CeBIT 2012, the Fleet Data Services software solution from STILL enables vehicle and driver data to be intelligently captured, formatted and made available online. Since February 2012 LMH has offered an extended logistics train programme, providing a more flexible way of optimising production, warehouse and transport logistics.
Represented by STILL, KION is participating in the IdentProLog research project, which is examining how to optimise the flow of goods by using radio frequency identification (RFID). The aim of the project is to establish consistent standards for RFID across the industry.
