Forklift Battery
Needs Analysis
- Extend continuous operation time to cover full shifts without battery swapping
- Implement opportunity charging capabilities to eliminate dedicated battery charging areas
- Enhance power output for consistent performance under heavy loads
- Integrate smart features for fleet management and predictive maintenance
- Ensure durability and safety in demanding industrial environments
Battery Specifications
- PowerLift Industries required a custom battery solution meeting the following specifications:Dimension: Standard 48V forklift battery size: 1028mm x 521mm x 784mm
- Weight: Maximum 1200 kg to serve as counterweight while maintaining maneuverability
- Voltage: 48V nominal
- Capacity: Minimum 1000Ah, with a target of 1200Ah for extended operation time
- Discharge Rating: Continuous discharge rate of 1C, with peak capability of 3C for 30 seconds to handle heavy lifting
- Chemistry: Lithium Iron Phosphate (LiFePO4) for long cycle life, safety, and fast-charging capability
- BMS (Battery Management System):Advanced cell balancing with individual cell monitoring
- Wi-Fi and 4G connectivity for remote diagnostics and fleet management
- Adaptive power management based on load and operational patterns
- Self-diagnostic capabilities with predictive maintenance alerts
- Certifications: UL 2580, IP65 rating for water and dust resistance
Solution Design
- We developed an advanced battery solution for PowerLift Industries:Utilized high-performance LiFePO4 cells with optimized energy density
- Implemented a rugged, shock-resistant enclosure with integrated thermal management
- Integrated an AI-powered BMS for intelligent power distribution and usage analytics
- Developed a proprietary ultra-fast charging system compatible with opportunity charging stations
Implementation Process
Collaborated closely with PowerLift’s engineering team through multiple design iterations
- Conducted extensive field testing across various warehouse environments and load scenarios
- Provided comprehensive support for integration with PowerLift’s forklift management software
- Performance Data:Operation time increased by 40%, from 6 hours to 8.5 hours on a single charge
- Charging time reduced by 80%, achieving 60% charge in just 30 minutes (opportunity charging)
- Lifting performance improved by 25%, enabling consistent operation with heavy loads
- Battery lifespan extended to over 4000 cycles, doubling the industry standard
Conclusion
This case study showcases our expertise in creating custom battery solutions for the demanding material handling industry. By addressing PowerLift Industries’ specific needs and exceeding their expectations, we’ve demonstrated our ability to deliver high-performance, reliable, and innovative power solutions that are driving the transition to more efficient and sustainable warehouse operations.
This custom battery solution has revolutionized our electric forklift lineup. The extended operation time and opportunity charging capabilities have been game-changers for our customers' operational efficiency. The smart features and improved performance have set a new benchmark in the industry, significantly enhancing productivity in warehousing operations.
