Like the song "Love and Marriage"...your forklift battery and charger should work with each other Replacing the internal combustion engine with cleaner power sources is a hot topic these days, and there are many new options for powering forklifts. Electric forklifts now account for about 60 percent of the forklift market, and the segment is growing. Naturally, the heart of an electric forklift is the battery, and lithium-ion forklift battery technology is attracting a lot of attention as the industry looks for more efficient and cleaner power transmission.
Lithium-ion batteries have many advantages over lead-acid batteries; such as being more energy efficient, and easier and faster to charge. A key advantage is that they can be recharged on the go, regardless of how much charge is left in your battery. You can charge them when you get the chance, which is what we call "opportunistic charging": you can charge the truck while it's stationary or when you're resting. If your operation allows for frequent recharging, you will not only enjoy additional benefits such as greater flexibility and longer operating times. You can also optimize the size of batteries and chargers to meet your operational requirements.
When considering purchasing an electric forklift or forklift fleet, you should weigh your options for powering and charging it, especially when considering new options that may be more cost-effective and greener.
When comparing the two, Li-ion batteries have a more efficient charging process and can save a lot of money over time. Below we explore how the lithium-ion battery charging process can benefit businesses now and in the future.
The Li-Ion battery only takes 1 to 2 hours to charge. This is in stark contrast to lead-acid batteries, which take 8 hours to fully charge and 8 hours to cool down.
Since lead-acid batteries are filled with a solution of electrolytes (sulfuric acid and water), they get very hot during charging, so they need ample time to cool down after charging.
Typical cooling time for lead-acid batteries is 8 hours, or one shift. Because of the time it takes for lead-acid batteries to charge and cool down, each forklift needs one lead-acid battery per shift.
So if your warehouse operates 24 hours a day, you will need 3 lead-acid batteries per forklift. Lead-acid batteries must be replaced every shift. This is a time-consuming, labor-intensive process that should be factored into the true cost of the battery.
Lithium-ion batteries do not require a separate charging compartment, nor do they need to be removed from a forklift or other material handling equipment to charge. Instead, a forklift operator can connect the battery to a charger while it is still in the forklift or other equipment.
The charging process for lead-acid batteries is much more complicated. Here's what it looks like:
● When the battery needs to be charged, the forklift operator must drive the forklift to the designated battery charging room.
● Using special lifting equipment (due to the weight of the battery), trained personnel must then remove the battery and place it on a storage rack for charging.
● Then charge the battery for about 8 hours.
● After the charging process is complete, the cooling phase begins. This lasts for an additional 8 hours.
● If the battery room requires space to charge other batteries, the batteries will remain where they are charged, or personnel can transport them to a designated cooling area.
● After the battery has cooled and is ready to be returned to service, personnel may check the electrolyte level and refill the battery with distilled or deionized water. Skipping this last step can lead to degradation of the chemical process and premature failure of the battery.
Implementing the use of lithium-ion batteries can save labor costs due to the simpler and less labor-intensive charging process.
Unlike lead-acid batteries, lithium-ion batteries do not require water to be added. This saves time and manpower that can be used elsewhere in your operation.
The Li-ion battery management system (BMS) also automatically balances the battery and provides various protections while the battery is charging. Battery management system:
● Keep the battery temperature within the ideal operating range to prevent overheating or freezing.
● Monitor current and voltage measurements to ensure both are maintained at safe levels.
● Prevents overcharging and dendrite formation, which can severely damage Li-ion batteries.
In lead-acid batteries, the water level must be precisely controlled in a number of ways. In addition to topping up when fully charged and cooled, crews must monitor batteries to ensure:
● The water level does not drop to the point where the top of the lead plate is exposed (approximately every 10 charge cycles)
● The pH of the water used must be between 5 and 7
● Leave enough space for the internal liquid to expand, which happens when the battery is in use
● Regularly balance batteries and control temperature throughout charging
Lithium-ion batteries have enhanced safety features to ensure you get the most out of your batteries while protecting your workers.
As mentioned above, lithium-ion batteries do not need to be filled with water during charging. When workers add liquid to lead-acid batteries, there is a risk of spillage. If a leak occurs, the highly toxic sulfuric acid inside the battery can splash on the body or in the eyes, causing injury.
Lithium-ion batteries have little risk of overheating during charging. The battery management system tracks battery temperatures to ensure they remain within safe operating ranges so they do not pose a risk to employees. In lead-acid batteries, the electrolyte solution can overheat, increasing the pressure inside the battery and causing damage to the plates...or worse, an explosion.
Lithium-ion batteries also emit no potentially harmful fumes while charging. Because of the risk of this happening, lead-acid batteries require a separate, well-ventilated area for charging.
When switching from lead-acid to lithium-ion batteries, we recommend that you research and map your fleet's charging habits to determine the potential for opportunistic charging. You can use our GPRS cloud fleet management tool to see where, when and for how long certain trucks have been used. When the truck is not in use, it can be charged. Good charging habits of the operator are very important. Best to have them charge the truck as soon as they're done driving. A good Li-ion powered vehicle charging pattern and schedule has many cost saving benefits such as using one lighter battery per truck instead of replacing batteries as often and buying fewer chargers, making your material handling cleaner, cheaper.
Now that you've observed the productivity of your fleet and its potential for opportunity charging, you can go a step further and consider how many chargers you actually need. We just mentioned that with a good charging plan, you don't necessarily need a charger for every truck. You can charge some trucks while using other trucks and vice versa. It takes some planning, but it's a very effective way to keep costs down when switching from lead-acid to Li-ion batteries. We recommend starting small, and you can always order and install extra chargers later in case you don't have enough charging capacity.
We have many types of chargers depending on your needs. If you have a small operation and fleet, a standard charger will suffice. However, if your operation is larger and your fleet is used more frequently, you may want to consider upgrading your charger to a larger model to better suit your needs. All of our chargers are designed to make it easy for your operator to charge the truck. That's why the chargers offered by BSLBATT battery have UL1564 certification special quality and design, making them safe and easy to use.
The technology behind lithium-ion and lead-acid batteries varies widely and affects every aspect of charging, including the time it takes for the battery to charge, the process, maintenance required, and worker safety.
All of these factors create hidden costs that don't always account for the true cost of the battery.
When comparing these two battery types, lithium-ion batteries clearly win in terms of efficiency, safety, and total cost of ownership.
To learn more about why lithium-ion batteries are revolutionizing the material handling industry, check out our article How lithium-ion forklift batteries are changing the game for the paper and packaging industry.
