Efficient management of industrial electric vehicles by means of static and dynamic wireless power transfer systems

Industrial companies are moving toward the electrification of equipment and processes, in line with the broader energy transition taking place across the economy. Particularly, the energy efficiency and, consequently, the reduction of environmental pollution of intralogistics activities have become a competitive element and are now an actual research and development objective. A wireless power transfer is a contactless electrical energy transmission technology based on the magnetic coupling between coils installable under the ground level and a coil mounted under the vehicle floor, and it represents an excellent solution to decrease the demand for batteries by reducing vehicle downtimes during the recharge. This work aims to define a methodology to determine the optimal positioning of wireless charging units across the warehouse, both for static and dynamic recharging. To this aim, firstly, a mathematical model of the warehouse is proposed to describe transfers and storage/retrieval operations executed by the forklifts. Then, an integer linear programming problem is applied to find the best possible layout of the charging infrastructures. The optimal solution respects the energetic requirements given by the customer and minimizes the overall system cost. The proposed approach was applied to optimize the installation in a real-size warehouse of a tire manufacturing company. Several scenarios were computer generated through discrete event simulation in order to test the optimizer in different warehouse conditions. The obtained results show that integrated dynamic and static WPT systems ensure a constant state of charge of the electric vehicles during their operations.