Nowadays, electric vehicles are one of the main topics in the new industrial revolution, called Industry 4.0. The transport and logistic solutions based on E-mobility, such as handling machines, are increasing in factories. Thus, electric forklifts are mostly used because no greenhouse gas is emitted when operating. However, they are usually equipped with lead-acid batteries which present bad performances and long charging time. Therefore, combining high-energy density lithium-ion batteries and high-power density supercapacitors as a hybrid energy storage system results in almost optimal performances and improves battery lifespan. The suggested solution is well suited for forklifts which continuously start, stop, lift up and lower down heavy loads. This paper presents the sizing of a lithium-ion battery/supercapacitor hybrid energy storage system for a forklift vehicle, using the normalized Verein Deutscher Ingenieure (VDI) drive cycle. To evaluate the performance of the lithium-ion battery/supercapacitor hybrid energy storage system, different sizing simulations are carried out. The suggested solution allows us to successfully optimize the system in terms of efficiency, volume and mass, in regard to the battery, supercapacitors technology and the energy management strategy chosen.

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This paper proposes an approach for the accurate and efficient parameter identification of lithium-ion battery packs using only drive cycle data obtained from hybrid or electric vehicles. The approach was experimentally validated using data collected from a BMW i8 hybrid vehicle. The dual polarization model was used, and a new open circuit voltage equation was proposed based on a simplification of the combined model, with the aim of reducing the number of parameters to be identified. The parameter identification was performed using NEDC data collected on a rolling road dynamometer; the results showed that the proposed model improved the accuracy of terminal voltage estimation, reducing the peak voltage error from 2.16% using the Nernst model to 1.28%. Furthermore, the robustness of these models in maintaining accuracy when new drive cycles were used was evaluated by comparing WLTC simulations with experimental measurements. The proposed model showed improved robustness, with a reduction in RMS error of more than 50% compared to the Nernst model. These findings are significant because they will improve the accuracy of model-based battery management systems used in electric vehicles, allowing for improved performance prediction without the requirement of recharacterization for different drive cycles or individual cell characterization.