This study investigates the dynamic behavior of a recently developed counterbalance forklift truck. The final objective is creating virtual testing tools based on numerical multibody models to evaluate the dynamic stresses experienced by the forklift family of interest during a reference operating cycle, defined by the manufacturer’s testing protocols. This work aims at defining sufficiently accurate and easy-to-implement modelling approaches and validation procedures. It focuses on a specific test, namely the passage of a speed-bump-like obstacle at high velocity, which represents one of the most severe conditions within the reference cycle. Indeed, unlike most of the other wheeled vehicles, forklifts typically do not have advanced suspension systems and their dynamic response is significantly affected by ground irregularities. To this end, a preliminary model of the complete forklift, featuring rigid bodies and a simplified tire–ground contact model, is implemented with a commercial software. Experimental tests are conducted on the forklift to measure the vehicle vibrations when running on the obstacle, for model validation purposes. After model updating, the results provided by the numerical simulations match the experimental data satisfactorily. Hence, the modelling and validation strategies are proven viable and effective.

In the past years, forklift manufacturers have started to hybridise their products under the worldwide interest toward electrification. This is generally made starting from existing standard products, and converting them into hybrid versions, rather than start from scratch and designing fully new vehicles. This approach involves several gaps from the inaccurate evaluation of the powertrain architecture and relative energy management strategy, up to a rough sizing of components. Therefore, this study suggests a structured methodology to follow, aimed to properly design hybrid forklift trucks. The first step is the analysis of the conventional working machine to hybridise, identifying one set of duty cycles. Then, the design of the new powertrain architecture, with a proper energy management strategy, and the definition of a numerical simulation model realised through a multiphysics object-oriented software package, to properly size the new powertrain components, and to verify energy and power flows. Finally, it is also presented a brief-cost-benefit analysis, as last verification of the proposed methodology, to verify the cost-effectiveness to bring the new products to the market. Results have shown the general feasibility of the operation since the significant reduction in fuel consumption is combined with sustainable costs of the new electrified components.

Bonelli 4.0 is a project intended to study new technologies incorporated in the spaces of a highly innovative company; Bonelli produces wooden fixtures. With the introduction of the Homag machine, the company has studied a new productive layout, improving the production system itself e totally re-modulating all the work commission management. In addition to the developed layout, the study has defined a new logic and a new process not only aimed at the highest quality, but also at the realization of a highly specialized and mechanized prototypical system. The machine in fact, as well as reducing the lung area and the warehouse (no longer present), has allowed by tests to create an innovative management of the fixture project. Indeed, compared to before the usage of Homag and Archimedes, the commission was managed in a traditional way with a really long series of steps. Today, however, it starts from the yard already with the defined project, ready to start the production. The testing has also proved, by the new design, three successful elements of the project itself: • Improvement of the productive process • Reduction of the processing time • Increase of the global safety conditions at work in the company.

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