Delta’s Inductive Charging Technology for Autonomous Tow Trains and Counterbalance Forklifts in Indoor and Outdoor Applications
With its MOOVair Wireless Charging Systems, Delta is supporting Neumaier Industry GmbH & Co. KG in implementing AGV solutions for both indoor and outdoor use.
As automation advances and the demand for reliability grows, industrial companies are under increasing pressure to design processes that are not only efficient but also disruption-free and low-maintenance. This is especially critical in intralogistics, the backbone of modern production operations, where smooth, uninterrupted performance is key—24/7.
In the age of Industry 4.0, where production facilities are becoming increasingly networked and digitally controlled, seamless and automated logistics within the factory is more important than ever. Every interruption, manual interaction, or charging pause results in lost time and potential efficiency setbacks across the entire production chain. That’s why smart, future-ready solutions are needed—autonomous, reliable, and flexible, whether for tow trains or forklifts operating indoors or outdoors.
However, in such semi-autonomous production environments, which operate around the clock and often at capacity limits, conventional charging methods quickly reach their limits. Systems that rely on manual plug-in and disconnection of charging cables no longer align with the demands of highly automated environments—where human intervention is minimized by design.
A significant technological leap forward is inductive (wireless) charging, which is rapidly becoming a central trend—especially for AGVs, autonomous forklifts, and outdoor logistics vehicles. Wireless charging delivers key advantages: no exposed contacts, high protection against dust, water, and cold, and seamless integration into automated processes.
These benefits are exactly what Neumaier Industry GmbH & Co. KG was seeking. The company has integrated Delta's MOOVair inductive charging solutions into autonomous outdoor tow trains and counterbalance forklifts.
The Challenge: Autonomous Charging at 80V Without Efficiency Loss
Neumaier Industry GmbH & Co. KG, based in Hofstetten in the Black Forest, is a leading mid-sized provider of customized intralogistics solutions. Its focus lies on tow train solutions and AGVs—particularly for outdoor applications. Their offering includes automated tow trains, forklifts, under-ride shuttles, pallet stackers, narrow aisle systems, conveyor technology, and warehouse management software—catering to a wide range of sectors, from the automotive industry to leisure.
In two major customer projects—an autonomous outdoor tow train and autonomous outdoor counterbalance forklifts—Neumaier was looking for an efficient, rugged, and maintenance-free 24/7 charging system. The key difficulty, especially for the tugger vehicle in the outdoor tow train, was the need for 80V power supply—a niche where very few reliable providers exist.
The Solution: Delta’s MOOVair 10 kW and 30 kW Wireless Charging Systems – Developed and Manufactured in the EU
After searching for qualified partners, Delta Electronics emerged as the ideal solution provider—not only able to support the required voltage range but also with strong product quality and reputation. As a global leader in power supplies and thermal management, Delta also offers IoT-based, energy-efficient systems for industrial automation.
With a wireless charging portfolio from 1 kW to 30 kW, Delta is one of the few manufacturers offering a robust and EU-compliant 80V-capable system. Developed in Germany and manufactured in high-tech facilities in Slovakia, MOOVair systems offer 95% efficiency and an IP69 rating, making them ideal for both indoor and outdoor use.
Project 1: Autonomous Outdoor Tow Train “Factory Train FT630”
In this project, a Linde P180 tugger was retrofitted for autonomous outdoor use, including fully automated loading and unloading of trailers and wireless battery charging. Delta’s 30kW MOOVair charger, designed for 80V operation, was selected.
The MOOVair 30 offers 300 amps of wireless charging with no mechanical contacts, eliminating connector wear and drastically reducing maintenance. Wireless energy transmission works up to 150 mm distance at 95% efficiency—ensuring consistent performance even with minor vehicle misalignments. Its IP69 protection allows safe outdoor operation.
The system also integrates seamlessly with fleet or warehouse management systems via Ethernet and CAN bus.
Additionally, multiple vehicles can share one charging station, maximizing flexibility and lowering space and infrastructure costs.
Project 2: Autonomous Outdoor Counterbalance Forklifts FE616
This project focused on converting Linde E16 forklifts for autonomous outdoor operation. Neumaier chose Delta’s 10 kW MOOVair wireless chargers.
The MOOVair 10 delivers up to 275 amps and offers the same contactless, maintenance-free charging benefits. It is ideally suited for operations with high charging demands and irregular usage patterns.
A standout feature is Delta’s proprietary Pad-Pad-Link (PPL) communication technology. Unlike Wi-Fi, Bluetooth, or infrared, PPL uses a magnetic field and operates outside the congested 2.4 GHz band, making it immune to radio interference and environmental contaminants like dust and moisture.
Its short-range precision ensures reliable data and power transmission, even in dense or harsh industrial environments—ideal for modern logistics systems.
Integration and Implementation
Integration of the Delta charging systems was done during the vehicle retrofitting process. Key system requirements included:
- Rugged design (IP69) for outdoor use
- No open electrical contacts (resistant to water, dust, and cold)
- Maintenance-free operation
- Reliable communication via Ethernet
- Fully automated charging without manual plugs
Both solutions met these criteria with ease. Thanks to the close collaboration between Neumaier’s development team and Delta’s technical experts, integration was smooth and efficient.
A Milestone in Future-Proof Intralogistics
These two successful projects demonstrate how modern wireless charging technology can take intralogistics to the next level. By using Delta’s MOOVair Wireless Charging Systems, Neumaier was able to implement robust, maintenance-free, and fully automated charging solutions—ideal for harsh environments and the needs of autonomous vehicles.
The systems not only maximize uptime and minimize downtime but can also be seamlessly integrated into existing processes. Together, Delta and Neumaier are setting a clear benchmark for future-ready, efficient, and sustainable intralogistics solutions.