The new battery-powered MHL820 BATTERY⁺

FUCHS made another milestone with the so-called “Powerpack“. This is a diesel/hydraulic add-on module that extends the range of applications of cable-connected electric machines and allows free movement between the mains connection points.

Now, FUCHS is taking electric mobility to the next level, with the MHL820 BATTERY⁺, which has been designed with sustainability, practicality and maximum flexibility at its core. 

Battery material handler for everyone

Thanks to its clever design, the battery module of the MHL820 BATTERY⁺ can be expanded in stages. FUCHS customers therefore only pay for the battery capacity they actually need. In the basic package, the installed lithium-ion batteries provide enough power to operate the machine autonomously for up to two hours. There is no loss of performance during battery operation.

The machine is charged in grid synchron operation, comparable to a laptop. As soon as the machine is connected to the local power supply, the batteries are automatically charged as required. No separate charger is required for this. This not only reduces the complexity of the machine, it also ensures many years of reliable operation. 

Automatic load peak shaving, in conjunction with the standard soft starter, it is not only easy on the local power grid, but also on the wallet. The perfect choice for anyone who needs an environmentally and economically friendly machine. On a practical note, the MHL820 BATTERY⁺ can also be operated at less powerful mains connection points. 

Selected FUCHS models can also be retrofitted with a battery module after purchase. A complete rarity on the market! With this feature, the MHL820 BATTERY⁺ is well equipped for a sustainable future.

Under the BLUE Evolution strategy, FUCHS is continuously expanding the product portfolio of emission-free handling machines with the utmost dedication. Keep an eye out for more upcoming models just like the MHL820 BATTERY⁺.

Interview with Dr. Achim Kramer, Lead Systems Engineer at Fuchs^®

Dr. Achim Kramer gave recovery a behind-the-scenes look at the development of the MHL820 BATTERY⁺ material handler, the special challenges involved, and the possible applications in practice.

recovery: Hello Dr. Kramer, would you please introduce yourself to our readers?

Dr. Kramer: Hello, yes of course. My name is Achim Kramer and I have been responsible for Systems Engineering at FUCHS for approximately three years. I studied Mechanical Engineering, specialising in Development and Design, at RWTH Aachen University. After my studies I first worked as a scientific assistant in the field of drive and propulsion systems for mobile machines and then took over, as a chief engineer, the management of this research department. Alongside this work I was also managing director of the Centre for Mobile Machinery, before ultimately moving to my present responsibilities at FUCHS.

recovery: What benefits over preceding models does the MHL820 BATTERY⁺ material handler offer?

Dr. Kramer: The MHL820 BATTERY⁺ is our latest development and is the first battery-operated material handler to feature a modular drive system. It is based on more than thirty years of experience in the field of battery-operated handling equipment and permits customers, for the first time ever, to use it both in semi-stationary mode with a mains connection and also with complete flexibility in rechargeable-battery mode - with the same undiminished output level in both cases. The MHL820 BATTERY⁺ thus augments the previous product range of classic diesel and electrically driven handling machines with a local, zero-emissions rechargeable battery-pack variant as a counterpart to our existing diesel power-pack type. Thanks to its modular structure, the capacity of the rechargeable battery pack is also flexibly adjustable within a broad range. The customer therefore pays only for the battery capacity he actually needs. And even if he is initially sceptical about whether he really needs the rechargeable battery pack, he can, depending on the particular model, actually retrofit it even after delivery of the machine. For customers, this therefore ensures total flexibility, enabling them to select the most suitable drive system to meet their requirements.

recovery: What were the main challenges during development?

Dr. Kramer: One of the greatest challenges during the development of this machine was, in fact, its modular system structure, which makes it possible to choose between the diesel machine, the electrical machine, the electrical machine with a diesel power-pack and the electrical machine with a rechargeable battery pack, while also integrating all the components of the upper carriage in such a way that the machine‘s swivel radius is not increased. In addition, from the start there was an aim to develop a battery-drive concept that would optimally combine the benefits of a cable-based electrical machine with the flexibility of a battery-operated material handler. The MHL820 BATTERY⁺ can be operated not only in purely battery mode but also in a so-called mains parallel operation mode, which automatically recharges the battery during operation without any additional charging equipment. Furthermore, this is possible without any performance sacrifices when compared with a cable-operated mode. In addition, this concept permits peak shaving, where the power to be supplied by the mains connection for operation of the material handler is reduced by the rechargeable battery pack providing high-dynamics support and smoothing any load peaks occurring. We have developed our own specialised software that controls power flow in the system and, in addition, takes over the conditioning of the rechargeable battery pack. This conditioning system keeps the battery within an optimum temperature range, with the result that full power can be demanded from the rechargeable battery pack even at lower ambient temperatures. The operator therefore needs to take no action in such a case. He can use the machine like any other FUCHS machine and the software takes care of everything else.

recovery: For what applications is the MHL820 BATTERY⁺ especially suitable, and for what applications has it in fact been designed?

Dr. Kramer: The MHL820 BATTERY⁺ has been developed primarily for use in industrial waste management, where the machine is usually operated cable-connected with cable link to a mains supply. Typical applications include, for example, feed to a shredder or a baling press. In this case, the machine obtains its energy directly via the cable. It will, certainly, occasionally be necessary to leave the semi-stationary workplace in order, for example, to load a truck or to tidy up the yard. It may sometimes be necessary for the machine to 'help out' elsewhere and provide flexible support for other machines. It is in precisely these situations that the MHL820 BATTERY⁺ shows its strengths. Thanks to the zero-emissions rechargeable battery pack, the MHL820 BATTERY⁺ in the standard rechargeable configuration is capable of operating independently for up to two hours at full performance. After this task has been accomplished, the machine simply returns to its intended location and is able to continue working there with a cable supply while the battery is automatically and quickly recharged.  As already mentioned, battery capacity can be scaled up or down, meaning that the machine can also be designed for more than two hours of battery operation, depending on the customer's requirements, the demands made on the machine, and on the application. 

recovery: How long are delivery times and how is demand for the MHL820 BATTERY⁺? How was the response at bauma, where you unveiled this machine?

Dr. Kramer:The response to the MHL820 BATTERY⁺ at bauma was very pleasing! We received a great many positive comments and had a large number of excellent talks, including several promising enquiries. Delivery times depend very heavily on component availability, this currently differs very greatly, especially in the case of electronic components and batteries. We are able, however, to complete specific projects within a very short time.

recovery: Thank you for the interesting insights!