trak® XchangeBattery changeover systems for charging stations

Similar to the illustration

Typical applicationsof HOPPECKE trak® Xchange

■ Centralised and decentralisedbattery charging stations

■ All size of battery and truck fleet

■ All vehicle types

■ All traction batteries

Motive Power SystemsReserve Power Systems

Special Power Systems

Service

Your benefits with HOPPECKE trak® Xchange

■ Customer’s tailor-made solutions

■ High time and costs savings

■ Safety – Adherence to technical and safety laws as well as labour protection

■ Optimal space utilisation – space saving systems

■ Modular and flexible system components suitable for all vehicle types

■ Manual and automatic powered changing system for all requirements

trak® XchangeBattery changeover systems for charging stations

Battery-powered electrical vehicles, used byindustry in shift operation, must be re-suppliedwith power, quickly and reliably, on completionof their period of duty.

This is usually done in several ways and may incertain circumstances take place several timesa day. Either the vehicle is connected to acharger, so that it is out of use for chargingduring many hours, or else the heavy batterieshave to be changed using a crane, a manualchangeover truck or fully-automatic poweredbattery changeover equipment.

The competent and professional team of theHOPPECKE system division designs, plans andinstalls battery charging stations and batterychanging systems. They always give considera-tion to supplying the most efficient use of avai-lable space, customers’ requirements and safety.

HOPPECKE offers 4 options. All options are de-signed to suit customers’ needs and to save timeand money. The design of a system is depen-dant on the numbers of batteries in operation, onthe battery dimensions and the truck types in use.

• Transfer Trolley Systems – trak® Xchange TU

• Manual Changing Unit – trak® Xchange MU

• Powered Changing Unit – trak® Xchange PU

• Fully-Automatic Powered changeoverequipment – trak® Xchange FU

HOPPECKE’s battery changeover systems areideally suited to remove the dangerous and time-consuming battery changeover at charging sta-tions. They offer quick, safe and effortless batterychanging.

trak® Xchange

The HOPPECKE System StrategyCustomer advice

trak® systems

trak® monitorBattery management

trak® Xchange Battery changing system

Charging stations

Technical training/seminars

Planning/Engineering

Project management,Turn-key solution

HOPPECKE-Service and installation

trak® Xchange TU

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■ Number of batteries in operation:

• Without limitation

■ Applications:• Light-duty operation • Normal operation

■ Duration of a complete batterychange:

• Less than 2 minutes

■ Physical effort:• Low

■ Battery types:• Suitable for 12V and 24V batteries

■ Truck types:• Suitable for powered pallet trucks and

low level order pickers with roller bedextraction

■ Required area:• Used in centralised battery changing

area offering area reduction

The trak® Xchange TU and TU-HAsystem are suitable for 12V and24V batteries and have beenspecially designed for poweredpallet trucks and low level orderpickers with roller bed extraction.With the aid of a height indicatorthe trak® Xchange TU-HA offersadjustable heights to accom-modate differing roll off heights ina single system.

The trolleys are fitted with a doubleroller bed removing the need tohave a spare battery slot andaiding quick battery changing. Alocking device ensures safe transitof the battery. trak® Xchange TUand TU-HA incorporate a system toovercome tyre wear offering heightand tilt adjustment.

Roller bed extraction

Locking device for safetransit

trak® Xchange TU

trak® Xchange MU

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■ Number of batteries in operation:• Suitable for users with up to 10 batteries

■ Applications:• Light-duty operation • Normal operation

■ Duration of a complete battery change:

• About 6 minutes

■ Physical effort:• Low

■ Battery types:• Suitable for batteries up to 750 kg or 2,500

kg depending upon the chosen host truck

■ Truck types:• Suitable for all kinds of trucks with roller bed

extraction (powered lift adjustment)

■ Required area:• Used in decentralised battery changing area

The trak® Xchange MU system isappropriate to users with up to 10batteries in operation and suitable forbatteries up to 750 kg when used witha hand pallet truck or up to 2,500 kgwhen used with a powered pallettruck.

Both truck types offer adjustable liftingwhich makes the system suitable forall kind of trucks equipped with rollerbed extraction. The manual changingunit incorporates gearing which mini-mises the physical efforts when mo-ving and replacing batteries. A lockingdevice also ensures safe transit of thebattery.

Roller bed extraction

Gear wheel

trak® Xchange MU

trak® Xchange PU

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■ Number of batteries in operation:• Suitable for users with 10 to 20 batteries

■ Applications:• Light-duty operation • Normal operation• Heavy-duty operation

■ Duration of a complete battery change:

• About 5 minutes

■ Physical effort:• None

■ Battery types:• Suitable for batteries up to 2,500 kg

■ Truck types:• Suitable for all kinds of trucks with roller bed

extraction (powered lift adjustment)

■ Required area:• Used in centralised or decentralised battery

changing area

The trak® Xchange PU system isappropriate to users with 10 to 20batteries in operation and for batteriesup to 2,500 kg.

The attachment is mounted to apowered pallet truck with adjustablelifting which makes the systemsuitable for all kinds of trucksequipped with roller bed extraction.The magnetic or vacuum extractionhead provides reliable, powerful andconsistent battery attachment duringthe complete battery changing. Thevacuum option allows operation withplastic or plastic coated batteries. Alocking device ensures safe transit ofthe battery.

Locking device for safe transit

Powered system

trak® Xchange PU

trak® Xchange FU

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■ Number of batteries in operation:

• Suitable for users with any quantity ofbatteries in different sizes

■ Applications:• Normal operation• Heavy-duty operation

■ Duration of a complete battery change:

• Within 3 minutes

■ Physical effort:• None

■ Battery types:• Suitable for all kinds of batteries

■ Truck types:• Suitable for use with all kinds of trucks

(powered lift adjustment)

■ Required area:• Used in centralised battery changing

area offering optimal space saving.Available in single to six levels high.

The trak® Xchange FU system issuitable for users with any quantityof batteries in any different sizes as well as for any kind of trucks.

The trak® Xchange FU system isavailable in single to six levels highwhich allows all spare batteries tobe located in the smallest area,allowing optimal space saving inthe charging station. The laserpointer and the joystick control en-sure a correct location and positionof the battery, saving changingtime and avoiding errors whichoccur in manual battery change-over and which can lead to injury.

On-board controls

Laser pointer for correctlocation

trak® Xchange FU

trak® monitorLonger life for traction batteries

Higher productivity is also obtained through theeven and optimal capacity utilisation of thetraction battery. trak® monitor ensures thatcapacity levels are maintained at their optimum,therefore visits to the charging station are lessfrequent.

By using an industrial serial standard inter-face and a real-time clock, it is possible to turntrak® monitor into a highly sophisticated mainte-nance tool.

By connecting a PC, easy access to stored data is obtained via graphic user interface. Analysis ofthe data gives a clear picture of battery utilisation,charging times and waiting times (battery chargedbut not in use). Misuse such as removal ofbatteries on charge or out of sequence can alsobe investigated, so that the necessary action maybe taken.

By linking stored data from the trak® monitorsystem with data from the trak® power chargersthemselves, a comprehensive and effectivemanagement tool is obtained.

trak® monitor is an automatic charging and dis-play system developed specifically for chargingrooms.

The trak® monitor display is linked directly to thecharger and shows the charging point number ofthe first battery to be used. The next batteries tobe used are placed in an electronic queue sowhen the indicated battery has been removed, thedisplay switches to the next fully charged battery.The vehicle operator is immediately able to seewhich battery he needs to take and place on hisvehicle for the battery changeover, ensuring thatthe battery will be fully charged. An audiblewarning system alerts the operator if an incorrectbattery is taken.

This procedure leads to systemised utilisation ofthe traction batteries and to maximise battery lifewhich can offer considerable savings in cost.

Further benefits from trak® monitor result in theavoidance of over or under use of batteries. Thisoffers a major reduction in the time and cost ofbattery maintenance associated with the over andunder use of batteries.

trak® monitor

A: Battery usage without trak® monitorB: trak® monitor directs driver to take right battery every time

Audible warning when wrong battery is selected

TAKE BATTERY 17

WRONGBATTERY!

DIAGNOSIS-REPORT

trak® monitor LED version trak® monitor LCD version

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HOPPECKE Batterien GmbH & Co. KGP.O. Box 1140 · D-59914 BrilonBontkirchener Straße 1 · D-59929 Brilon-Hoppecke

Phone: + 49 (0) 29 63 61-0Fax: + 49 (0) 29 63 61-4 49

Email: motivepower@hoppecke.comInternet: www.hoppecke.com

HOPPECKE subsidiaries and factories - European sales and service network

Further information on www.hoppecke.com

• Low-maintenance and no-maintenance batteries

• Innovative battery chargers based on the latest technology

• Battery accessories

• Battery management systems and software

• Battery changeover systems

• Battery/charger servicing

• Battery recycling

• Applications engineering and technology

• Battery room design

• Technical training and seminars

• Leasing

• Power by the hour

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