Before the benefits of lithium battery technology are fully utilized, major forklift manufacturers will need to really redesign their forklifts 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 finally adopt 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 automatic guided vehicles and mobile robots (AGV and AMR), which rely largely on durable "non-interference" lithium batteries.
Now, lithium batteries can become an integral part of forklifts, or third-party modular lithium batteries manufactured by professional companies 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. Users do not need to choose from a variety of choices, nor do they need to maintain 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
The reason why lithium battery systems win is that they can better serve the personalized needs of customers and make the customization of material handling equipment higher. 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-ion integrated forklifts entered the market in 2014. However, in 2022, the sales volume of forklifts 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
Forklifts with integrated lithium batteries will be more expensive than ordinary electric forklifts with lithium batteries from battery professional companies. The price of a forklift with an integrated lithium battery solution may be twice that of an electric forklift with an 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 homework. At present, there are few forklifts with integrated lithium battery packs, which does not encourage the use of these forklifts in applications with non-standard operations, which usually require higher battery capacity to power accessories, move and lift heavy objects, or support longer working hours.
Some European brands of forklifts that use lithium batteries first may be very popular in their domestic market, but they are less attractive in the United States. It is precisely for this reason: the "standard" capacity of several models in their product line. In many cases, customers need "more oil in the fuel 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 advantage of the integrated lithium battery is that the forklift is designed with a lower center of gravity, which improves stability, operability and speed. These forklifts can safely handle heavier goods and require less counterweight.
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 its own facilities -- for example, the pallet elevator used for box transportation by commercial forklifts.
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 a 480v three-phase charger with an output power of 120-300a.
IP65 grade
Intrusion protection of water and dust 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 multi shift work 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
It is important that all three elements of the equipment forklift, battery and charger are fully integrated to maximize efficiency and safety. One engineering solution could be to create a locking system. However, you can also make all elements universally compatible!
The control and indicator of the forklift use battery data and improve the safety of the operator. Seamless can integration of battery and charger provides maximum charging efficiency and minimizes energy loss.
The integrated lithium battery solution provides all these benefits in a locked system, but so do OEM approved batteries and chargers. In fact, some OEMs outsource batteries for their systems, offering the same models you can buy in the market as part of their brand's (more expensive) lithium first solution.
All customers will definitely benefit from the development of common standards for can integrated batteries and forklifts and chargers. Closed systems stifle competition and drive up prices. No one is satisfied with a 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 a high voltage.
The future of comprehensive lithium battery solutions is very promising. But before taking full advantage of the benefits of lithium technology, major OEMs will need to really redesign forklifts around this new power source, and in the coming years, embedded solutions will still be more effective and economical.
