Efficient and fatigue-free order picking with elobau and STILL

Efficient warehousing processes are especially important for logistics providers. Order picking plays a crucial role, particularly in times of increasing range of variety and variants.

High stock turnover under time pressure in a large area means the operators of industrial trucks have their hands full. This applies especially in the distribution centres of the food trade or in the automobile industry. During the development of its new order picker, STILL GmbH focused on operating comfort to facilitate efficient work. A central part of the concept is the STILL EASY Drive steering wheel. For the development and production of the innovative operating element, the company relied again on their long-term partnership with elobau.

STILL and elobau develop innovative steering wheel for industrial trucks
As one of the world's leading manufacturers of industrial trucks, STILL GmbH − according to the company’s own statement − places great value on developing vehicles that simplify work for the user. For the order pickers of the OPX product line and other vehicles, an operating concept was to be developed that set new standards in terms of ergonomics and robustness. The result is a steering wheel similar to that found in a car which, at first glance, might appear better suited for a Formula 1 car than an order picker. It allows both left-handed and right-handed operators to easily steer the vehicle, move forwards and backwards, operate hydraulic functions as well as actuate the horn and brake − all with one hand and without repositioning.

Proven partnership and new challenges
Having placed the basic design of the steering wheel in the hands of long-standing design partner Teams Design from Hamburg, the premium manufacturer turned to elobau for the realisation and production. STILL and elobau share a long history of working together. In 2005, the German specialist for sensor technology and operating elements produced the first multi-function lever for the reach truck produced at that time. From 2010 until 2014, both companies then worked closely together on a multi-functional joystick for reach trucks and counterbalanced trucks.
In designing the steering wheel for the OPX models, the developers from elobau worked not only with the STILL company headquarters in Hamburg, but also with the firm's production facility in Luzzara, Italy.

A hard core for maximum loads
Tipping the scales for the cross-border cooperation were, above all, the competence and experience of the elobau developers. "After we demonstrated that we can meet the high strength requirements that STILL had in mind for the steering wheel, the decision was made to work together with us, even on an international basis," recalls Mario Halwachs, Key Account Manager Material Handling at elobau. Because the strength of the components is unique on the market: the steering wheel can withstand a load of more than 2,000 newtons without deforming. "The high robustness was a central requirement for guaranteeing our customers low maintenance costs," explains Jürgen Wrusch, trade press officer at STILL GmbH. During the design process, it was important to ensure this strength and, at the same time, integrate both elements for vehicle control − including electronics − in the steering wheel with zero backlash. elobau implemented these requirements by using a welded component consisting of three parts. The developers used FEM analyses (Finite Element Methods) to prove that the self-supporting construction would withstand the desired load.

Everything within reach: all operating elements are provided on the Easy Drive steering wheel twice in a mirrored arrangement. As a result, both left-handed as well as right-handed users can steer the vehicle with one hand and operate all function buttons without repositioning. With the drive control directly integrated in the steering wheel, the driver determines whether the vehicle moves forwards or backwards while steering without needing to release the steering wheel. © STILL GmbH

Step-by-step from concept to series production
Challenges arose during the project, primarily due to the high complexity of the components. "A steering wheel that consists of a single part on which all functions can be operated with one hand without repositioning has not been available on the market in this form up to now," explains Mario Halwachs. Two developers for the mechanics and two for the electronics, together with the team from STILL, brought the project from concept to series production in a development time of nearly three years. In an iterative process, there was ongoing development, testing, redefinition of requirements and the development subsequently adapted. To test whether the steering wheel would actually meet the ergonomic requirements, elobau constructed fully functional prototypes for usage tests by STILL.

Brand-specific look and feel
An important basis for the flexible process was, according to Mario Halwachs, elobau's high level of vertical integration: "From the development services and tool manufacturing to the plastic injection moulding plant and even cable assembly, we can do a great deal ourselves, thereby keeping the number of suppliers to a minimum − even with this project," he explains. For example, the company's own tool manufacturing facilities developed and manufactured more than 50 tools for the subsequent series production so that the punched plastic parts seamlessly interlock on the steering wheel. Keeping the high quality look and feel that the customer knows from other STILL vehicles was a requirement. A coating of foamed polyurethane on the steering wheel offers drivers grip and comfort even after longer periods of use. The degree of hardness of this so-called soft-touch coating, as is found on other STILL vehicles, is also among the parameters that were periodically amended during the development phase.

A well-protected electronic heart
In addition to the strength and operating comfort, another requirement from STILL was that the electronics of the steering wheel be protected in accordance with protection class IP67. This means that absolutely no dust can penetrate the electronics from the outside and that the components could theoretically be submerged up to one meter under water. In practice, the high standards are also due to the fact that the industrial trucks are used in, e.g., refrigerated warehouses. Even larger temperature difference must not, therefore, result in condensation affecting the electronic components. Because of the one-handed operation, the centre console had to be below a certain size. The creativity and experience of the developers was called upon due to the limited installation space. For example, to seal the main board under the display from both above as well as from below. To facilitate this requirement, a test was first performed to determine what was possible, given the small installation space.

Innovation with the end customer in mind
The new OPX models were presented by STILL as the "sports car of the horizontal order pickers" in Luzzara in September 2017. For Jürgen Wrusch, the result of the development partnership is a complete success: "The STILL Easy Drive steering wheel allows our customers to work more efficiently and safely with the STILL OPX order pickers in warehouses. The possibility to operate all functions without needing to reposition saves drivers time and offers an optimum overview. We are pleased that the concept was also very well accepted by our customers − we had pre-orders for the new OPX models before they were available. As with our previous projects, the collaboration with elobau worked extremely well, even on an international level. The STILL Easy Drive also hit the mark with trade experts.It has been nominated for the IFOY AWARD of the Materials Handling and Intralogistics Association in the VDMA in the "Special of the year” category.

For further information, please visit: http://www.elobau.com/en-gb/news/still-lenkrad-fuer-flurfoerderzeuge-opx