It took some time to develop the parts for the Prius, so it is understandable that Toyota took the same time to develop special forklift parts for the world’s first internal combustion electric hybrid forklift. An IC-electric hybrid forklift is not a simple matter of putting two systems next to each other on the same vehicle. Adjustments are needed to get optimal performance from both the internal combustion engine and the electric motor, and then make them work compatible with each other.
How the hybrid IC-electric works
The two energy sources in a hybrid can be combined in different ways. One, a Parallel Hybrid has the fuel tank that supplies diesel to the engine and the battery that supplies power to the electric motor. Both can simultaneously turn the transmission that turns the wheels and lifts the load. In the other type, a standard hybrid, the engine does not directly power the transmission. Instead, it spins a generator that powers the battery or electric motor. Then the electric motor turns the transmission. Some forklifts use a series system for driving and a parallel system for loading.
The hybrid forklift has a diesel engine that is smaller than usual and designed for minimal CO2 emissions. A hybrid has a very advanced electric motor with sophisticated electronic systems that allow it to act as both a motor and a generator. It draws power from the battery and returns it. The transmission in a hybrid works much like the transmission in a normal diesel forklift.
Main launches of IC-electric hybrids
Launched in December 2009, the Toyota Geneo-Hybrid is a 3.5 ton counterbalanced forklift. It combines a 2.5 liter diesel engine with a 26 kilowatt electric motor and a nickel hydride battery. It is said to reduce fuel consumption and CO2 emissions by 50%. The truck uses a series hybrid system to drive and a parallel hybrid system to handle loads. The latter receives mechanical energy from the diesel engine and generator, and electrical energy from the battery. The battery does not need to be plugged in to recharge it, but it recharges as the engine runs.
Since then, other companies have developed hybrid IC-electric forklifts. Mitsubishi Heavy Industries launched a 4 to 5 ton hybrid forklift in 2011. It boasts of a unique powertrain design with a lithium-ion battery, a low-emission diesel engine, two induction motors, and an inverter. Komatsu introduced a 2-ton forklift that has reduced the number of major forklift parts by more than 30%. It claims a 20% reduction in fuel consumption and CO2 emissions. Proton Power Systems plc launched a triple hybrid forklift that combines a fuel cell, battery and super capacitors resulting in 50% energy savings. Anhui Heli Company exhibited a 7-ton hybrid forklift with a lead-acid battery and supercapacitors, the first industrial hybrid vehicle in China. South Africa’s Kipor produces a 3.5 ton hybrid forklift.
The IC-electric hybrid forklift is a relatively recent development. For this reason, forklift parts directly related to its hybrid nature are available only from manufacturers. However, as hybrids become more common, you can expect a sufficient supply of aftermarket hybrid forklift parts to be available.
