Efficient airside cargo handling depends upon speed, flexibility and teamwork. Tight schedules and the demands of time sensitive cargoes mean that a rapid turnround is vital, as well as the need to cope with a range of loading options such as nose loaders, main deck side loading or lower cargo holds. The answer was found in the application of technology. Thanks to continual refinement and innovation there is now a wide range of loaders available and able to cope with all types of freight carrying aircraft.
In recent times the technical challenge has been made more complex by an increasing need to demonstrate good “eco” credentials, particularly on the airport ramp. In an effort to achieve the goal of zero emission requirements, vehicle manufacturers are turning towards electric variants of their vehicles, including use of fuel cell technology, while retaining features that customers have come to expect of the Diesel powered version.
JBT Corporation is a well established supplier of loading equipment and has always been in the forefront of technical innovation so it was no surprise when, in June 2011, it was announced that its JBT AeroTech business had teamed with InnovaTek and EnerFuel in the development of a Fuel Cell Range Extender for battery-powered airport ground support equipment. JBT AeroTech will collaborate with InnovaTek, a leader in fuel processing technology, and EnerFuel, a fuel cell developer, during Phase I to establish the technology’s feasibility to reduce the emissions and fuel costs of airport ground support equipment. The project’s overall objective is to develop a fuel cell power system capable of converting Bio-Jet fuel to electricity for the on-board recharging of an electric vehicle’s battery. Upon successful completion of the first phase, the project will be eligible for follow-on grants to develop, demonstrate and commercialise the product.
Meanwhile the Company offers it successful Commander family of loaders. The Commander 15i features the HeliRoll conveyor system and has a lift capacity of 7,000 kgs). It provides main deck and lower lobe container loading capability for a wide variety of passenger and freighter aircraft. The loaders are available in a standard, wide and universal configuration. With a larger engine and load sensing hydraulic system the Commander 15i has increased fuel savings of up to 60 per cent of loaders using smaller engines.
JBT AeroTEch has been offering electric versions of the Family. The Commander 15i electric is an electric version was developed to meet zero emission requirements and maintain all of the popular features that have made the Diesel powered Commander a popular loader in the industry. The Commander 15i Electric was designed to maintain all of the key features and benefits of the Commander 15i, while introducing the unique features and benefits of an electric loader. The use of identical operational controls makes the difference in power source transparent to equipment operators familiar with the diesel version. The design includes a maintenance free AC drive motor, 160V Electric System, Electronic Controller and two standard 80 volt batteries. The Commander 15i Electric is available as a new model or as a conversion kit for the Commander 15 1996-203 models.
JBT AeroTech recognises that one of the biggest concerns for customers with electric loaders is battery duty cycle. The Commander 15i electric’s efficient operating system has been proven to drive long distances and operate on several flights before recharging.
A more heavy weight performance is provided by the 30i with a lift capacity up to 15,000 kgs.
Similarly, the Commander 40i cargo loader (formally known as the Commander 30i 20T) also uses the latest technology to provide platform-lifting capabilities of 20,000 kg for all main deck freighter and lower lobe wide body aircraft. Like other members of the Commander family, the Commander 40i offers a swing out power module with an Onboard Diagnostic System (ODS), HeliRoll conveyor system and fail safe controls. An patent pending LIFTsmart closed loop automatic lifting system ensures smooth uplifts and improved stability for heavy or off centred loads.
In 2010, JBT AeroTech introduced the all-new Commander 60i as a direct replacement for the MDL-60, first introduced in the mid-1970’s. This heavyweight member of the Family provides platform lifting capabilities of 30,000 kg for main and lower deck loading and features all the regular Family functions. A longer rear platform has enough space for three 98 x 128 ULS’s and the heaviest loads are conveyed efficiently as the HeliRoll conveyor system covers the complete platform together with a fragile lift mode to handle sensitive shipments.
LAWECO Maschinen- und Apparatebau GmbH produces the Cargo Master Loader Transporter CMLT 3.7-3.6, a highly flexible and manoeuvrable vehicle, equally suitable as a loader as well as a transporter for containers and pallets. The Cargo Master Loader CML 7 has been reworked and is now considered to be among the most innovative, efficient and safe loaders available. The Cargo Master Loader CML 14-5.6 to CML 3.5-5.6 range includes Main Deck Loaders of 14 ton and 35 ton specially designed for widebody aircraft cargo handling and are considered to be a particularly suitable solution for nose loading of the Boeing 747 as well as for the loading and unloading of the main cargo deck of the Airbus A380.
The SCHOPF product range includes the 7-ton LoadStar 070 that was developed for loading and offloading cargo loads in lower and main decks of all civilian aircraft currently in use. A natural development led to the LoadStar 140. This cargo loader provides main deck and lower lobe container loading capability for a wide range of aircraft. Compared with smaller loaders the Loadstar 140 saves loading and offloading time and can handle all pallets and containers up to a weight of 14 tons and a length of 20 feet.
The HC100 lifting transporter combines the functions of a ULD transporter and a loader in one simple unit. With a lifting capacity of 7 tons, the height-adjustable platform can accommodate all standard ULDs, as well as being ideally suited to handle outsize loads of every description.
TLD is a Company that likes to demonstrate its “green” credentials having had main deck electric loaders (929 type) in operation since 2000. However, these TLD Green units were plugged to the grid rather than running on batteries.
More recently, that was developed to enhance the autonomy and battery life for battery-powered loaders. The main goals were to operate with the speed and power of a Diesel loader for a full day of heavy operation up to and beyond the handling of 250 containers, before having the need to re-charge.
The result was the TLD TXL-838-reGen, 7-ton battery powered loader and it is keeping its promises. TLD engineers had studied the science of battery technology and those aspects of their use that limit their autonomy and longevity. This demonstrated the need to control the average current draw to a minimum level and particularly the peak current draw that are unavoidable effect when lifting an elevator. These current peaks result in limiting the batteries capacity between charges. At the same time, TLD studied how to re-use the energy that was available in the lowering of the loader’s elevator. The studies result is a system that reclaims energy and uses it to supplement the battery during its next lift. Also patented by TLD was a method of managing the energy flows through the use of Supercapacitors. The Supercapacitors are able to absorb and return energy to the system at a very fast rate, compared with other energy storage devices.
The result is a loader that can run two to three times as long between charges as any other loader on the market today and with a similar advantage for extended battery life. The TLD TXL-838-re-Gen demonstrates these ideas in action with TLD claiming that it is the only current, battery powered loader that represents a one for one replacement of a diesel loader.
In addition, the Company’s TXL-838-SUP (Superior) is a self-propelled, dual-platform loader designed to transfer containers and pallets weighing up to 16,700 lbs. With the ability to interface 70″, 100″, or 140″ doors, this heavy-duty loader can be used to service a wide range of aircraft, including the Boeing 747 and Airbus A380.
The full range of vehicles, produced by TLD, include the TXL-737, TXL-838, 929 Series and the 121 Series. The latest being the 121-S a self-propelled, dual-platform loader designed to transfer 20 ft ULD’s weighing up to 36 tons with the ability to interface 254 cm, or 356 cm doors. It features the Grasshopper lift systems which distributes the stress equally on the platform and the chassis. In order to handle the additional weight capability the hydraulic system operates at a higher pressure than in earlier models.
In Germany, Trepel Airport Equipment GmbH offers a product range of units with payloads from 3.5, 7, 14, 20, 30 to 35 tons. Trepel Sales Director, Carsten Schimkat, told AI that thanks to standardisation of the cargo high loaders’ design, the Company can react quickly to customer needs and offer short-term delivery dates.
The CHAMP 200’s scissor integrated cylinders (the only one without vertical cylinders for lifting/lowering rear platform) and the low front platform height makes handling easy. The CHAMP 300, one of the biggest loaders manufactured by TREPEL, is fast and extremely robust. With its cylindrical roller system on both platforms it is prepared for all climatic conditions. The most recent addition to the product line, the CHAMP 350, is described as the most capable high loader in the world.
The continuous increase in weight of oversized cargo has been making more demands on ground support equipment. Trepel has met this challenge with its 35 ton capacity main deck loader. Not only does the CHAMP 350 offer 35 tons lifting capacity on the main platform, this also applies to the front platform. New technical features such as hydraulic adapters, twin wheels, telescopic driver‘s stand and a new lifting system on the front platform make the CHAMP 350 an advanced loader of its kind, compatible with all freighter types, including the new Boeing B747-8 Freighter.
In keeping with the current green requirement, Trepel has produced the CHAMP 70WE, the electric version of the CHAMP 70 together with the 70S that is a wider version.
Schimkat said “The CHAMP 70WE can be fitted either with a 625 Ah permanently installed lead/acid battery or a 400 Ah removeable battery, using the quick, battery change system PLUG-I-O, with an easy access dolly for quick recycling. The latest lithium battery technology is now under development and was trialled on a 70We at Frankfurt”.
A lithium battery reduces charging time by a factor of four and has a longer life expectancy compared with a conventional battery. Carsten Schimkat sees Lithium as the long-term solution for electric vehicles and Trepel is in the forefront of this technology.
Not all hi-lift vehicles are dedicated to cargo, some manufacturers look to the equally demanding role of catering supply and replenishment. Typically, Mallaghan Engineering Ltd produces two such vehicles – CT4000 and CT 6000. The CT4000 will service aircraft with sill heights ranging from 1.3m to 4.2m. The CT6000 will service aircraft with door sill heights ranging from 2450mm to 5900mm, in other words from 737 up to A330, A340, A300 and B777 with a full width platform.
Similarly, AMSS Aircraft Maintenance Support Services supplies the AMSS/Norco lift “XL” MKII type Scissor Lift, designed for use with both commercial and military aircraft as a catering vehicle, for cabin cleaning, maintenance, or as an ambulift. The scissor mechanism can be mounted on any suitable commercial chassis, and various cab modifications are available.
Several options are available including modifications and interior fittings to customer specifications.
In the “hi-lift” world the customer is spoilt for choice!
