Before the benefits of lithium battery technology are fully utilized, the major forklift manufacturers will need to really redesign the forklift around this new power source, and in the next few years, this embedded solution will maintain higher efficiency and economy.
After decades of engineering evolution around the only power source technology (lead-acid battery), electric forklifts and forklifts have finally adopted a new power source: lithium-ion battery pack. The benefits of lithium ion solutions are now well known higher performance, less maintenance and better sustainability. Lithium batteries provide a better return on investment and make possible the use of autonomous guided vehicles and mobile robots (AGV and AMR), which largely rely on durable "non-interference" lithium batteries.
Now, the lithium battery can become a component of the forklift, or a third-party modular lithium battery pack manufactured by a professional company can be used. Will integrated or modular battery packs become the standard? This problem is very important for the future development of material handling equipment.
In consumer devices driven by lithium batteries (such as mobile phones), integrated batteries are the current standard choice. The user does not need to choose from a variety of choices, nor does he need to carry out any maintenance on the battery; One size fits all users. But for professional tools and equipment, modular removable batteries can usually do better. This method is related to material handling equipment.
Integrated forklift battery
Lithium battery systems win because they can better serve the personalized needs of customers and make the material handling equipment more customized. A single forklift model can be used for outdoor or internal logistics operations, perform all functions under extreme ambient temperatures, or use power hydraulic accessories instead of ordinary forks all because the modular lithium battery system can be adjusted for each operation. Electric forklifts powered by lithium batteries can now be used in applications that used to use only diesel and propane powered forklifts.
In the United States, the first batch of lithium battery integrated forklifts entered the market in 2014. However, in 2022, the sales volume of forklift trucks with integrated lithium batteries is still in the double digits, and battery professional companies sell thousands of lithium battery equipment every year. What hinders the development of forklift manufacturers?
cost
The price of forklift with integrated lithium battery is higher than that of ordinary electric forklift with lithium battery of battery professional company. The price of forklift with integrated lithium battery solution may be twice that of electric forklift with American brand industrial lithium battery pack.
Product series
In the US market, few enterprises can be considered as "standard". Many are traditionally multi shift and weekend assignments. At present, there are few forklift models with integrated lithium battery pack, which does not encourage the use of these forklifts in non-standard operation applications, which usually require higher battery capacity to power accessories, move and lift heavy objects or support longer operation time.
Some European brands of forklifts that use lithium batteries first may be very popular in their domestic markets, but they are less attractive in the United States. It is precisely for this reason: the "standard" capacity of several models in their product lines. In many cases, customers need "more oil in the tank", and these batteries can only be provided by professional lithium battery manufacturers.
Ergonomics
Since the lithium battery pack is much thinner than the lead-acid battery pack, these forklifts are "built around the battery", which can reduce the area of the battery compartment. This leaves more space for the operation room, provides more leg space, and makes it easier to enter and leave.
An important benefit of the integrated lithium battery is that the forklift is designed to have a lower center of gravity, thus improving stability, operability and speed. These forklifts can safely handle heavier loads with lower counterweight requirements.
Integrated charger
Some of these forklifts are equipped with built-in 110V chargers. It is very useful when the equipment needs to be carried around and the material handling equipment must be charged outside of its own facilities -- for example, the pallet elevator used by commercial forklifts for box transport.
When a large battery is involved, the 110V charger with an output of 20-50a is not powerful or fast enough. Fast and efficient charging definitely requires a more powerful external charger. Class I and II elevators usually use 480v three-phase chargers with an output power of 120-300a.
IP65 grade
Protection against water and dust intrusion is essential in some operations and is a very useful function. In many cases, such as meat and fish processing plants, material handling equipment also needs to perform optimally in multiple shifts at low ambient temperatures. Advanced insulation performance keeps the battery warm, combined with high capacity to support long-term operation. Only special lithium batteries are available, and they are not on the menu of forklift manufacturers.
Can integration
Importantly, all three elements of the equipment forklift, battery and charger are fully integrated to maximize efficiency and safety. An engineering solution could be to create a locking system. However, you can also make all elements universally compatible!
Forklift controls and indicators use battery data and improve operator safety. Seamless can integration of battery and charger provides maximum charging efficiency and minimizes energy loss.
Integrated lithium solutions provide all these benefits in locked systems, but so do OEM approved batteries and chargers. In fact, some OEMs outsource batteries for their systems, providing the same models you can buy in the market as part of their brand (more expensive) lithium first solution.
All customers will definitely benefit from the development of the common standard of can integrated battery and forklift and charger. Closed systems stifle competition and drive up prices. No one is satisfied with a mobile phone locked to an operator and an expensive charger with a unique connector.
The future of forklift integrated lithium battery
With the progress of higher voltage forklift batteries (around 400V), the energy efficiency of material handling equipment will be greatly improved. However, in addition to safety issues, the main obstacle for forklift manufacturers at present is the availability of the entire range of electric components. The power system will need to be redesigned to reliably support such high voltages.
The future of comprehensive lithium battery solutions is very promising. However, before taking full advantage of the benefits of lithium technology, the major original equipment manufacturers will need to really redesign the forklift around this new power source, and in the next few years, the embedded solutions will still be more effective and economical.
