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PROPOSAL:

Execute Contract to Demonstrate Fast Charging of Electric Forklifts

SYNOPSIS:

Edison EV has applied fast charging technology to re-power electric forklifts. Successful commercialization of this technology will enable forklift operators to replace many of their internal combustion engines with batteries. Through this project, the viability and benefits of fast charging in forklifts and other applications will be demonstrated. Total project cost is $187,200. AQMD’s contribution shall not exceed $60,000. The remaining balance will be co-funded with $94,200 from Edison EV, and $33,000 from the forklift operators.

COMMITTEE:

Technology, August 28, 1998. Vice Chair Leonard Paulitz and Roy Wilson communicated their concurrence.

RECOMMENDED ACTION:

Authorize the Chairman to execute a contract with Edison EV to demonstrate fast charging of electric forklifts in an amount not to exceed $60,000.

Barry Wallerstein, D.Env.
Acting Executive Officer

Background

Electric forklifts constitute more than half the total population of forklifts. The remainder consists of internal combustion engines, powered by gasoline, diesel, or propane. In a wide variety of instances, users would prefer electric forklifts but are thwarted by the high cost of maintaining multiple batteries for each truck, a battery charging room, and lost productivity from having to change batteries during working hours. The application of fast charging technology to forklift fleet operation would eliminate these difficulties.

Norvik Traction Inc., has developed a technology wherein the battery is charged to the maximum extent possible without exceeding the battery’s ability to accept the charge. This advantage results in significantly decreased charge time. Fast charging of forklifts differs from fast charging of automotive electric vehicles. Sophisticated battery management devices are installed on electric vehicles to regulate the charging activity. This results in the vehicle controlling the charger actions. No such sophistication is available on forklift batteries. Hence, Norvik has created an integrated system that allows the charger to become interactive with the industrial battery and use fast charge rates.

Proposal

Edison EV, working with Norvik Traction Inc., will apply Norvik’s fast charging technology to the operation of forklifts. The main objective of this project is to demonstrate the applicability and benefits of fast charging industrial batteries in forklift fleet operations, and establish the viability of replacing forklifts powered with internal combustion engines in selected applications.

The demonstration would involve the installation of three 33 kW Norvik Traction conductive fast charging systems in a minimum of two forklift fleet users located within the South Coast Air Basin. Industries may include manufacturing, food & beverage, and retail distribution centers. The lift trucks will be retrofitted with a kit to allow fast charging and battery monitoring, and Edison EV will supply one new battery for each truck and guarantee the level of battery pack performance for the project duration. The demonstration will be for approximately 90 days at each location.

Benefits to AQMD

The proposed project is included in the September 1997 update of the Technology Advancement Plan under Project 97M2-8, "Development and Demonstration of Electric Off-Road Equipment." The AQMP relies on the expedited implementation of advanced technologies in Southern California to achieve air quality standards.

There are currently little or no emissions control requirements for these engines, and implementation of this new charging technology will enable forklift operators to replace some or all of the fuel-burning internal combustion engines in their fleets. The subsequent emissions benefits can be significant. In addition, the operators of forklifts will also be motivated to use this technology as a result of increased productivity, increased safety, reduced battery maintenance, and elimination of the need for additional battery storage.

This technology can also be applied to on-road vehicles with less sophisticated on-board electronics like golf carts and other similar types of vehicles.

Sole Source Justification

Section VIII, (B)(2) of the Procurement Policy and Procedure identifies four major provisions under which a sole source award may be justified. This request for a sole source award is made under provisions B.2.c.: The desired services are available from only the sole source, and B.2.d.: Other circumstances exist which in the determination of the Executive Officer require such waiver in the best interests of the AQMD. Specifically, these circumstances are: B.2.c.(1) the unique experience and capabilities of the proposed contractor or contractor team, and B.2.d.(1) project involving cost sharing by multiple sponsors.

In terms of the unique experience and capabilities of the contractor team, Norvik Traction Inc., has developed and patented the charging hardware and the battery management system. This technology is the first commercial system that actually makes the fast charger the slave to the battery in charging electric forklifts. Utilizing sophisticated interface electronics the charger constantly monitors the battery and adjusts the current throughout the charging process.

In terms of cost sharing, Edison EV and some forklift fleet operators are cosponsoring this demonstration project and are providing valuable cost sharing which leverages AQMD's contribution to a ratio of 1:2.

Edison EV has been working with Norvik Traction Inc., on fast charging technology for electric forklifts and is the exclusive sales and service provider for this product throughout all of North America. It has done extensive market research prior to its involvement with this technology, and has found a number of forklift users interested in this charging system.

Resource Impacts

The total amount of AQMD funding for this $187,200 project will not exceed $60,000. Total project cost and cost sharing from other cosponsors are as follows:

Sufficient funds are available in the FY 1998-99 Budget, from revenues received from the state-mandated Clean Fuels Program. The Clean Fuels Program, under Health and Safety Code 40448.5 and 40512 and Vehicle Code 9250.11, establishes mechanisms to collect revenues from mobile and stationary sources to support projects to increase the utilization of clean fuels in both sectors, including the development of the necessary advanced enabling technologies. Funds collected from motor vehicles are restricted, by statute, to be used for projects and program activities related to mobile sources that support the objectives of the Clean Fuels Program.

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