Due to increasing needs for efficiency, safety and sustainability in global warehousing and logistics operations, electric stackers are an important alternative to traditional internal combustion and manually lifted equipment. Electric stackers are now found in warehouses, manufacturing facilities, grocery stores and distribution centers because they are chargeable, quiet, produce zero emissions, and have a compact physical size. Electric stackers use an electric motor which has become one of the key points of innovation and differentiation in the industry.
Electric stackers use usually two basic electronic motors; a drive motor and a lift motor. Drive motors provide the propulsion needed to operate the machine, and lift motors provide the capability to handle loads vertically. Both drive and lift motor types must provide high torque at low speeds, great start-up characteristics, and a rapid response to variable load conditions. The electric motor landscape is currently dominated by AC induction motors or Permanent Magnet Synchronous Motors (PMSM). PMSM's are being deployed in premium stackers more every day due to their high power density, increased efficiency and lower energy consumption.
Motor systems are evolving toward compact, intelligent, integrated and dedicated solutions to address size and control challenges associated with modern stackers. The integration of motors and controllers may simplify vehicular architecture and assembly efficiency in certain configurations. Intelligent motors equipped with Hall sensors and encoders enable robust speed and positioning control, which is valuable.
Support for standard communication protocols such as CAN or RS485 enables ease of interconnectedness with fleet management and smart warehouse systems, which allow for real-time monitoring, diagnostics, and predictive maintenance.
The operating environment of electric stackers also contrasts internal combustion stackers as electric stackers undergo significant start-stopping, heavy lifts, and overall, likely non-steady state, conditions. Manufacturers increasingly need to design motors that experience the rigours of rarely being turned off (unless recharging) and remain energy efficient and reliable, partly by exploring new designs, new materials, and improved magnetic circuit configurations to improve performance and longevity.
The growth of world-wide e-commerce and smart logistics will likely continue to support the electric stacker market, and significant opportunities and expectations will emerge for motor manufacturers. Motor suppliers must ensure they remain competitive by developing fit-for-purpose, high-efficiency and smart solutions to meet the contemporary requirements of next-generation warehousing and material handling equipment.
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