Development of an efficient and robust wireless inductive charging system for material handling electric vehicles

Project Information

MagCharge

Grant agreement ID: 190173479

DOI

10.3030/190173479

Project closed

EC signature date 20 May 2022

Start date 1 March 2022

End date 29 February 2024

Funded under

• The European Innovation Council (EIC)

Total cost

€ 3 546 405,00

EU contribution

€ 2 482 483,50

Coordinated by

MAGMENT GMBH
Germany

Periodic Reporting for period 2 - MagCharge (Development of an efficient and robust wireless inductive charging system for material handling electric vehicles)

Reporting period: 2023-03-01 to 2024-02-29

Summary of the context and overall objectives of the project

A constantly growing number of warehouses is being equipped with autonomous vehicles such as AMRs, AGVs and autonomous forklifts that support human workers. Most fleets include several additional vehicles that compensate the vehicles that are picking up a charge and are not available for operations during this time. Usually for example AMRs need to charge an average 5 minutes per hour in a 24h shift. The extra number of vehicles and the largest possible battery capacity are thus needed to ensure smooth operations. Project MagCharge addresses this problem and aims to increase sustainability and productivity in logistic hubs such as warehouses by integrating dynamic wireless charging infrastructure that enables vehicles to pick up a charge while moving. The infrastructure is based on Magment’s recycled magnetic concrete material. By equipping around 2-5% of a warehouse floor with MagCharge this static charging process can be eliminated, the battery capacity can be reduced by up to 2/3 and the number of vehicles can be optimised dramatically. Furthermore, essential space that was used for parking and charging vehicles can now be used for existential operations. As a result, less vehicles and reduced battery capacities mean reduced fixed costs and a better footprint at simultaneously optimized productivity which is key to the intralogistics segment.

Work performed from the beginning of the project to the end of the period covered by the report and main results achieved so far

Magment has made real technical proof of concept of the MagCharge including stationary and dynamic wireless charging technology with all system components. To achieve this we upgraded and developed the Magcharge subsystems and components along with integration of functional system. Magment’s unique magnetic concrete based primary coils designs were further optimised for dynamic charging of electric forklifts and the required tuning, power electronics and controls to drive the system were developed. Magcharge electronics were integrated with the magnetizable concrete coil systems.

The demonstrator validated charging parameters and the design specifications and demonstrated dynamic wireless charging and the principle of work. It comprised of: two dynamic wireless charging primary pads (Tx pads), fitting tuning capacitors for each Tx pad, high frequency (HF) inverters with fitting software, system control and algorithm, Rx coil with proper housing for electric forklift and board charger fitted to charge 24V lithium-ion batteries.

Progress beyond the state of the art and expected potential impact (including the socio-economic impact and the wider societal implications of the project so far)

Magment´s MagCharge systems demonstrated the following benefits to customers and warehouse solution providers:
- High performance: Up to 95% charging efficiency
- No downtimes
- Minimized battery pack by 1/2 to 2/3
- Time-saving by avoiding manual charging or battery change (battery swapping).
- Reduced vehicle cost
- Fast integrable, robust and durable infrastructure
- Saving conventional battery chargers.
- Use of self generated energy
- Peak load reduction.
- Reduction of repair costs.
- Maintenance/service costs of dynamic charging system included.
- Reduction of battery maintenance effort for lead-acid batteries
- Reduced need of number of vehicles keeping the size of operation same (Optimized fleet size by reducing vehicle requirement by 25%)

Dynamic wireless charging demonstrator

Shows dynamic wireless charging system concept rendering