IFOY Audit
Finalists undergo the three-stage IFOY Audit as part of the IFOY Audit, which takes place during the TEST CAMP INTRALOGISTICS. This consists of the scientific IFOY Innovation Check, the IFOY Test and the jury test.
IFOY CATEGORY
Warehouse Truck „highlifter“
IFOY
2016
EKX 516
Jungheinrich
Product name and company
EKX 516 – Jungheinrich
Category
Warehouse Truck „lowlifter“
Description
Jungheinrich presents the new 80-Volt high rack stacker EKX series 5. It was exclusively developed for operation in very narrow aisles and can be used for loading and unloading pallets or pallet cages as well as for order picking individual items.
Very narrow aisle warehouses are designed to create highly optimized storage space by halving aisle widths, thus – in contrast to wide aisle warehouses – doubling the amount of pallets that can be accommodated on the same space. At the same time, the use of narrow aisle trucks allows for tripled lifting heights of up to 17,500 mm.
The EKX truck is a completely newly developed electric order picker/tri-lateral stacker. As a so-called man-up stacker, it lifts the load upwards with the driver to ensure flexible and safe operations. Compared to the previous model, the loading capacity increased by 100 kg to 1,600 kg, while the lifting height was raised by 0.5 m to a total of 17.5 m, thus rendering the EKX 514-516 benchmark in the market.
Besides the new and unmistakably striking design, the characteristics of the EKX include an intelligent lightweight construction, an innovative system for vibration damping as well as a new drive technology based on synchronous reluctance motors. These newly developed drive technologies by Jungheinrich constitute a quantum leap in terms of energy efficiency by reaching the highest possible efficiency level of IE3 in forklift operation.
Innovations
Efficiency:
Lowest fleet consumption in its class and longer operating times due to the latest synchronous motor technology.
Top performance: Maximum lifting speed was increased by 20 percent from 0.5 m/s to 0.6 m/s, traverse speed up to 0.5 m/s.
Higher, already standardized base and residual load capacity (+100 kg) thanks to reduced truck weight using intelligent lightweight construction.
Latest technology
The new system for vibration damping increases safety and improves handling on uneven floors. This allows a 30-percent higher driving speed.
Ergonomics:
More cabin space and more freedom of movement for each driver thanks to the latest operating concept.
Easier, electrical height and tilt adjustment of the control panel.
Convenient and quick climbing into and off the truck due to the lowest entry in its class.
Flexibility:
Optimum adaptation to any application requirements thanks to six individually selectable performance modules.
Increased process reliability and time saving in pallet handling through seven modular configurable assistance systems.
Flexible expansion of the application areas from the manual to the semi- and fully automatic operation.
For further details please refer to the attached 3D tool.
Market relevance
The new EKX’s objective was to ensure better coverage of all market segments and secure our leadership of customer benefits, in order to expand Jungheinrich’s current market share.
For this purpose, a new platform concept was developed, which facilitates demand-oriented customization thanks to intelligent modularization and high variant diversity. Additionally, the new EKX is supposed to advance our position as intralogistics innovation leader. This entails a further reduction of energy consumption and the use of new technologies, such as the novel vibration damping system for improved compensation of unevenness on the floor as well as a ultra-modern, ergonomic workplace.
Customer benefits
The main advantages for decision maker are that the new motor technology, together with the lightweight design that allows an unprecedented energy efficiency of the truck. In practical terms this means: two-shift operations without battery change, a 2Shift1Charge guarantee and thus cost savings of € 7,000 per annum. In line with the “Industry 4.0”, the vehicle is fitted with modern RFID technology, communicating with the customer’s ERP system. An integrated connection to the customer’s IT system is also guaranteed. This allows the connection of assistance systems such as the Jungheinrich Warehouse Navigation, which facilitates a 25-percent increase in the warehouse’s handling capacity.
The driver also benefits from more freedom of movement – especially in the footwell. A switchless two-handed operating concept ensures increased comfort and safety of the operator. Lynchpin of the workplace is the electrically adjustable control panel. As the central control and information unit, it offers a variety of advanced features. These include a color display and a membrane keyboard with numeric keypad. Via access code, the operator can retrieve individually adjusted drive programs. Thus, the freely selectable performance modules and assistance systems can be directly controlled.
Other information
| This is a | Vollständig neues Modell |
| Date of market launch | 03/01/2016 |
| Competitive products | Still MXX Linde K Toyota BT C15 |
| Special equipment IFOY test device |
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Technical data
| Drive type | Elektro |
| Lifting weight max. | 1400, 1600 kg |
| Truck weight | 7900 kg |
| Driving speed without load | km/h |
| Lifting speed without load | m/s |
| Lifting height max. | 17500 mm |
Test report
With the introduction of the new EKX 5 series, Jungheinrich has raised the bar in the segment of high rack stackers. New motor technology, a state-of-the-art control concept and lightweight design generate further improvements in the area of energy efficiency, and an innovative concept dampens mast vibrations.
The new narrow aisle stacker can lift loads of up to 1,600 kg, 100 kg more than was previously the case in this segment. Maximum lifting height is 0.5 metres higher than the predecessor model at 17.5 metres.
The new machine is the first warehouse truck equipped with a new motor technology developed for the intralogistics sector – the synchronous reluctance motor. These motors use the power generated by a changing magnetic resistance (reluctance), and roughly 93 percent of the energy is converted into output – thereby halving energy losses. According to the manufacturer, this further reduces energy consumption by 15 percent compared to the predecessor model. In combination with the lightweight design of the cabin, this results in significantly improved energy efficiency. The targeted energy savings of 15 percent were not achieved in the IFOY test, however. The test team assumes that consumption will be lower in daily use following fine-tuning of the control system for the hydraulic functions. This was also confirmed by a comprehensive real-world trial comparing the predecessor model with the new EKX, in which the new EKX 516 was slightly more cost-efficient and 10 percent more productive.
Thanks to the improved energy efficiency, Jungheinrich is able to guarantee that the trucks can handle two-shift duty with just one battery charge without any problem. This renders spare batteries, changing stations, expensive tools and time-consuming personnel deployment unnecessary.
With the launch of the new EKX series, Jungheinrich presents the new, patented “Floor Pro” system for the dampening of mast vibrations for the first time. The system enables the user to work conveniently, safely and efficiently at heights of up to ten metres on non-optimum floor surfaces – also with an approx. 30 percent increase in speed. “Floor Pro” also protects the load and the truck, as it reduces vibrations and therefore the risk of damage. This in turn means less frequent servicing and maintenance. The mast movements are noticeably smoother, and the truck has a powerful feel.
When working on floors that are not absolutely flat and that are not really suitable for the use of high rack stackers, the optional Floor Pro module significantly reduces mast and cabin sway, which means the truck can also be used in a wider range of different warehouse zones.
The new EKX 516 has various modules for process optimisation in the warehouse to promote efficiency of use. These include warehouse navigation and RFID as well as height and distance measurement. WMS orders can be sent wirelessly to the truck terminal via the Jungheinrich logistics interface. As in the predecessor machine, the interface translates the commands and forwards the information directly to the vehicle control system. The truck is aware of its current position and the position of the next job. It automatically identifies the most efficient diagonal route, and all the driver has to do is drive off.
In addition, the EKX boasts a spacious cabin with well-arranged control panels and ample storage space for work and personal items.
IFOY Test verdict
With the new EKX, Jungheinrich has improved its top product in the high rack segment. The new technology saves energy, and thanks to Floor Pro the narrow aisle stacker can also be used effectively on uneven warehouse floors. The EKX 516 achieves maximum efficiency when used in combination with a warehouse navigation system.
| Hard facts | Test Truck IFOY Test | Average other trucks | Value 1 to 10 | |
| Productivity Max mode | 339.23 | 309.93 | Pallets p. 8 hrs | 8 |
| Productivity Eco mode | NA | NA | Pallets p. 8 hrs | |
| Energy level Max mode | 13.3 | 13.4 | kWh 100 plts | 7 |
| Energy level Eco mode | NA | NA | kWh 100 plts | |
| Driving speed with load | 10.4 | 10.4 | km/hr | |
| Lifting speed with load | 57.5 | 52 | cm/sec | |
| Swivel speed | 11.1 | 10.3 | Left to right | |
| Averages soft facts | ||||
| First impression | 8.40 | |||
| Load Safety | 6.50 | |||
| Entry to truck | 7.29 | |||
| Seat & Sit position | 8.00 | |||
| Legg Space | 8.50 | |||
| Activate truck | 8.50 | |||
| Hydraulics | 7.75 | |||
| Steering | 7.71 | |||
| Sight | 7.50 | |||
| Driving acceleration | 8.00 | |||
| Driving braking | 8.00 | |||
| Driving & Turning | 8.00 | |||
| Parking truck | 7.57 | |||
| Safety elements | 8.25 | |||
| General after test | 8.00 | |||
| Sustainability | 8.00 | |||
| Totals | ||||
| Total average soft facts | 7.87 | |||
| Total productivity | 8.00 | |||
| Total Energy consumption | 7.00 |
IFOY Innovation Check
Market Relevance
The Jungheinrich EKX 514-516 is a highly developed industrial truck for the extremely common activity of storing goods in narrow aisles. The first-time use of the Jungheinrich-developed drive motor based on the familiar synchronous reluctance motor principle has benefits in terms of the overall energy consumption of the EKX 514-516. It takes account of the needs of users, who aim to deploy the truck over two working shifts with one battery charge. There are high demands not only on productivity when using these machines but also with regard to functional safety in the narrow lanes that are part and parcel of shelf storage concepts. Productivity levels were confirmed in the quantitative tests. When it comes to functional safety, Jungheinrich has developed an advanced system for vibration damping that ensures improved handling on uneven flooring by preventing and cushioning the vibrations of the extended mast.
Thanks to its persisting high level of market penetration, the electric narrow aisle forklift with man‑up function is of major relevance both for order picking and for three-sided operation in the warehouse itself as well as in the pre-storage area. The new and optimised properties meet the requirements of users, and the market relevance of the machine can therefore be described as very good overall.
Customer Benefit
The explicit customer benefit derives from the special properties of the truck in narrow warehouse aisles. Both the achievable high driving performance and the avoidance of excessive oscillating motions promise a good customer benefit in terms of transshipment, as do the savings in energy and hence costs due to the systematic use of energy-efficient components. Moreover, the new functions of the PSA allow simultaneous operation of multiple narrow aisle stackers of this type in a single lane. This is made possible by a safety control system of the sensor manufacturer.
The vehicle falls in line with the familiar Jungheinrich concept of tried-and-tested control elements and diagnosis functions. It therefore also provides an implicit customer benefit in the form of the uniformity of the said functions within the context of a fleet from the same manufacturer. Overall, the customer benefit is to be described as very high, as the performance-related functions, the energy efficiency features and the functionality of the safety devices have been implemented in an excellent fashion.
Degree of Novelty / Innovation
The degree of innovation is extremely high, as this kind of oscillation damping in a direction transverse to the direction of travel was previously unknown in narrow aisle stackers. The implementation concept is also extremely compact and is combined with a further function integrated in the cushioning mechanism. In addition, the further development of this known truck type also included weight reduction at the mast, and this further helps to counteract the oscillations.
A further innovation is the way in which the familiar principle of the synchronous reluctance motor is employed. The EKX 514-516 is the first time that this motor principle has been systematically implemented in a series-produced industrial truck.
Functionality / Type of Implementation
In purely technological terms, the aforementioned innovations and functions have been well implemented. The oscillation avoidance and cushioning feature was impressively demonstrated during the field test. The compact implementation of this damping function without any increase in length of the mounting bracket in the direction of travel and the integration of a transfer device active on both sides of the aisle underline the expertise of Jungheinrich in the field of vehicle design and specifically as regards this type of machine.
| Functionality / type of implementation | + |
| Novelty / Innovation | ++ |
| Customer benefits | ++ |
| Market relevance | ++ |
| ++ very good / + good / Ø balanced / – less / — not available | |
Image/video credits: Jungheinrich AG
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Statutes
In den Statuten sind die Grundwerte und die Standards des IFOY AWARD festgelegt, nach denen die Organisation handelt. Dazu gehören unter anderem Gremien, Wahlomodus, Bewertungskriterien sowie der Code of Conduct.
Committees
The International Intralogistics and Forklift Truck of the Year has three bodies: Jury, sponsors, and advisory board.