Simulation and experimental validation of a hybrid forklift truck

The need of reducing energy consumption and polluting emissions, in response to the growing worldwide environmental interest, has raised the demand of more efficient machines. Many working machines manufacturers have started to consider alternative solutions of their products. This paper shows the development of a hybrid version of an existing forklift truck built by Toyota Material Handling Manufacturing Italy. It has been modelled and simulated a new series-hybrid powertrain, with a Diesel-fed internal combustion engine and a lithium battery. Simulations were performed on realistic duty cycles, and the main sub-models experimentally validated. A comparison between the new hybrid configuration and the conventional one, in terms of fuel saving and combustion engine sizing, has been discussed.