Sennebogen has introduced a new "Green Hybrid" system for its 835 and 845 series material handlers, specifically designed for high-cycle scrap and port handling operations. Material handlers work on a unique duty cycle: they constantly lift heavy loads vertically. When lowering the grapple, the potential energy of the load is normally dissipated as heat through the hydraulic system. Sennebogen's engineering team has developed a way to capture this lost energy.
The system uses an "Ultracapacitor" module mounted on the rear counterweight. When the operator lowers the boom, the hydraulic cylinders act as pumps, pushing oil through a hydraulic motor connected to a generator. This generator charges the ultracapacitor. When the operator commands the boom to rise, the stored energy is instantly released to power an electric assist motor, supplementing the diesel engine's power.
Unlike traditional batteries, ultracapacitors can handle rapid charge and discharge cycles millions of times without degradation, making them ideal for the stop-and-go nature of scrap handling. The system also features a "Zero-Engine-Mode" for idle times. When the machine is stationary but the operator needs to rotate the upper structure to spot a load, the diesel engine automatically shuts off, and the ultracapacitor powers the swing motor. This drastically reduces noise and fuel consumption during the loading process.
