Since the beginning of the new millennium, the Indian market for lift trucks has seen several advances in technology including cleaner engines, separately excited DC traction motors, electronic controllers for battery powered lift trucks, etc. The pace of advance has only accelerated and Godrej Material Handling has remained at the forefront of all new advances striving to bring new technologies for its customers as soon as they are viable and affordable.

At every CeMAT India exhibition, Godrej has showcased new products and technologies aimed at making material handling operations more energy efficient, environment friendly, operator friendly, cost-effective and safer. The company's philosophy over the years has focussed on finding innovative yet practical solutions to material handling challenges of customers.

In CeMAT 2010, Godrej is showcasing several interesting solutions leveraging new technologies.

Leveraging the Power of AC Technology

Godrej Material Handling has very successfully deployed AC motor technology on battery powered forklifts and warehouse trucks since 2008. The main benefits of AC motors are smooth operation, superior control in the hands of the operator, high reliability, maintenance free performance, high energy conservation and their ability to deliver the same level of performance even with reducing battery charge.

The company has recently advanced this one step further with a new 2-tonne AC electric forklift with a turning radius of only 1.8 m (6 ft). This class leading turning performance is possible because:

• The front wheels are driven independently by 2 AC motors with integrated gearboxes
• The traction control system of each motor is synchronised to create an 'electronic' differential which is capable of turning the drive wheels in opposite directions to generate an extremely tight turning radius, and
• A completely new steer axle that complements the twin motor drive system to reduce the turning radius dramatically.

The result is a forklift that turns virtually on-the-spot, greatly improving manoeuvrability and reducing the stacking aisle width.

Energy-saving Hydraulics

Lifting and steering hydraulics in electric counterbalanced forklifts are conventionally operated by independent motors.

Though this has been the norm for decades, the system is not very energy efficient because the pumps operate in On/Off manner, delivering either the full oil flow or none. When full flow is not required the excess is returned to the tank, wasting energy and wearing the motor and pump.

Godrej Material Handling has recently introduced a new hydraulic system, which includes an electronic controller.

The controller operates the motor at the optimum speed to deliver just the amount of oil demanded by the operation whether it is lifting, tilting or steering.

This energy saving system gives users' about 10% more operating time on each battery charge, reduces power consumption and defers battery replacement.

Further, the operator has superior control of all hydraulic operations and this translates into higher productivity and safer handling. This system allows the manufacturer to customise hydraulic performance to users' application and performance needs.

Hydraulic Lift Cushion

All lift trucks use a lifting system that employs hydraulic cylinders. Since the lift operation takes place in 2 or 3 stages with different cylinders operating at each stage, there is a thump or mild jerk during stage switchovers.

While it may not be a cause for concern in most general purpose applications, it is not desirable while handling delicate goods or while working at height, besides creating a small impact on the structure of the mast (or upright). Godrej Material Handling has recently developed and introduced a hydraulic design that acts like a cushion at the point of stage switchover. The result is a smooth, virtually stepless, lifting and lowering action.

Equally important, softening the lifting and lowering cycle makes for a happier and more productive operator.

Oil Immersed or 'Wet' Disc Braking Systems

Godrej Material Handling has deployed oil immersed disc braking systems on diesel and electric forklifts. The main advantages of wet disc brakes over conventional drum brakes are:

• Significantly lower inertia than drum brakes; they act much faster ensuring quick and safe braking
• Larger radiating surfaces make them run cooler; the service interval is 8,000 to 10,000 working hours - that's nearly 4-5 years of normal operations, and
• Discs occupy less space making the entire brake assembly very
• compact.

Disc brakes have long established themselves as the preferred braking system for automobiles and as a natural consequence, they find application in heavy construction and material handling equipment.

Godrej offers wet disc braking systems on 1.5 to 6 tonne diesel forklifts and on electric forklift models.

It has always been the endeavour of Godrej Material Handling to bring affordable technology advances that help customers compete more effectively in their markets.

Godrej will showcase all these products and technologies at CeMAT 2010.