Explosion-protected electric forklifts: as powerful and intelligent as standard models

Some industries, such as electric motor and battery manufacturing, are currently experiencing a boom. The European Chips Act promotes the construction of semiconductor factories in Europe in order to reduce dependence on Asian suppliers. Consequently, large semiconductor manufacturing facilities are being built in various locations. These factories use hazardous and highly flammable substances. Companies are also setting up ATEX-certified areas for recycling electronic waste and batteries. Explosive atmospheres can develop in these areas, too, so the use of appropriately protected industrial trucks is required. Linde MH’s compact three-wheeled electric forklifts are especially well suited for use in confined warehouse and production environments, while its four-wheeled electric forklifts offer high maneuverability and maximum stability, even on uneven surfaces.

The same Look & Feel

Safety is paramount for explosion-protected vehicles. Linde MH leverages its position as an original equipment manufacturer in this sector and others. For instance, converting takes place in close proximity to the company’s series production facility in Aschaffenburg. This physical and conceptual proximity is why Linde MH can bring explosion-protected versions to market more quickly. “We order the first prototypes right from the pilot series. We have access to all the development documents and can therefore quickly present the explosion-protected model for the more demanding zone 1/21 to our customers,” explains Elke Karnarski, Product Manager EX-Proof Trucks & Safety Solutions at Linde MH. Flame-proof housings containing electronic components are installed in such a way that they do not alter the vehicle’s contours. This ensures that the forklift operator’s visibility and legroom are not obstructed by an additional housing mounted on the rear of the vehicle or in the footwell. “Operators benefit from the same look and feel, as well as the many new comfort features they’re familiar with from series-production vehicles,” Karnarski says.

Double safety for zone 1/21: Sensors measure the temperature directly at the motor

“Maximum safety with highest performance” is the motto that sums up the guiding principle of Linde MH developers. The intralogistics specialist does not use standard motors in its explosion-protected models. According to Elke Karnarski, the engineers and product developers have “gone the extra mile” when it comes to safety in zone 1/21. Production areas where hazardous substances are mixed or transferred have a higher probability of developing an explosive atmosphere. Therefore, it is crucial to precisely monitor the temperature of all heat-generating components. Two measures ensure that the temperature limit is maintained while keeping the motor’s performance on par with that of a standard vehicle. Karnarski explains, “For zone 1/21, we have installed motors with special windings and higher insulation classes to meet the stringent safety requirements for these ATEX zones. In addition, we have integrated the sensors directly into the motor winding. This enables us to continuously measure the temperature right where it is generated.”

Linde MH has introduced new three- and four-wheel versions of explosion-protected electric forklifts, designed for use in ATEX zones 1/21 and 2/22.

Linde MH has introduced new three- and four-wheel versions of explosion-protected electric forklifts, designed for use in ATEX zones 1/21 and 2/22.

Safety first, even when reversing

Upon request, Linde MH’s explosion-protected models can be equipped with either a Reverse Assist Camera or a Reverse Assist Radar. Both systems enhance safety during reversing. The camera has been trained using AI to distinguish between people and objects. However, the system’s true intelligence is revealed in the way the forklift responds. As Elke Karnarski explains, “The vehicle detects how far away a pedestrian is and initiates braking accordingly. Additionally, the driver receives an audible warning, enabling them to react quickly. This buys valuable seconds to prevent an accident.” The Reverse Assist Radar reduces the vehicle’s speed and can even bring it to a complete stop. “The radar takes into account the vehicle’s speed, the load on the forks, the steering angle and the distance to the object – whether it’s a mesh box, a person walking behind the vehicle, or another forklift crossing the rear area. The system calculates the braking distance and applies the appropriate amount of braking force,” says product manager and explosion protection expert Karnarski.

Additionally, the Linde Safety Guard assistance system facilitates the creation of different speed zones. When the forklift enters a defined ATEX zone, its speed is reduced automatically. Once the forklift exits the zone, the operator can accelerate back to a higher speed. In zone 2/22, the Linde Safety Guard can also be used to implement mutual warning signals for intersecting forklifts. The combination of automatic speed reduction and audible and visual warning signals further mitigates the risk of accidents.

Linde MH also offers a variety of lighting solutions that enhance safety in narrow, poorly lit and confusing warehouse and production facility aisles by illuminating the surroundings and alerting other employees to an approaching forklift truck. These solutions include VertiLights, LED stripes and red warning lines projected to the sides of the vehicle. All of these solutions are available for explosion-protected vehicles as well.

Extra comfort feature: Heated driver’s cabin

Maintaining a high level of attention at all times is paramount for employees who handle hazardous substances. A comfortable cabin climate and clear windows both contribute to employees’ well-being and safety. The new explosion-protected electric forklifts are equipped with a special blower heating system featuring eight nozzles for the windshield, interior and footwell. This fully integrated system is certified for zones 2/22 and 1/21 and has been designed to provide optimal comfort and safety. On top the vehicle is equipped with a preheating function that ensures the cabin is warm for the driver as soon as they enter.