Lithium-ion forklift trucks – are they right for you?

Lithium-ion batteries are not a new technology – we find them in our mobile phones, laptops, tablets, electric vehicles, and electric toothbrushes to name but a few. Research on this form of rechargeable battery dates back to the 1960’s with the first prototype developed in 1985 and commercialised in 1991.

One industry that is seeing a growth in the use of lithium-ion technology is logistics and forklift trucks but is this a technology you have considered? Is it even right for you and your operation? In this article, we will explore the world of lithium-ion batteries, chargers and their role in the intralogistics industry compared with traditional lead-acid batteries.

Lead-acid or Lithium-ion?

There’s no real right or wrong answer to this, it really does depend on your shift operation as to which of the two main battery types are best for your logistics operation.

Below you can see an overview of the two technologies.

Keep charging, stop changing

Unlike lead-acid batteries, lithium-ion batteries remain directly in the forklift truck during the charging process and are charged via a plug connection.

The charging process in multi-shift operations is characterised by frequent fast and opportunity charging of the lithium-ion battery - for example during lunch breaks.

Removal of the battery from the forklift truck, as is the case with lead-acid batteries, is not necessary. The required charging infrastructure for lithium-ion batteries can therefore be placed flexibly and in a space-saving manner along the flow of goods.

Safe and stable CAN communication

With lithium-ion batteries, the charging process is largely controlled by the battery management system (BMS).

For the charger to communicate safely with the battery, a CAN protocol is required. The Fronius BatteryLink was developed specifically for this purpose. Operators of electrically powered forklift trucks can use it to seamlessly integrate lithium-ion traction batteries into their workflows and optimise existing processes.

With Fronius BatteryLink, "plug & charge" becomes reality. After implementing the communication protocol, all you need to do is drive your forklift truck to the charging station, plug it in and start charging. Through an automatic baud rate detection, the charger adapts individually to your lithium-ion battery. The intelligent battery charger automatically detects the battery voltage as soon as it is connected, no additional settings are required.

Fast charging in the lead-acid world

Lead-acid batteries are particularly suitable for single-shift operations or for companies with sufficient time for charging, changing, and maintaining the forklift battery.

As orders increase and the forklift fleet grows, operations usually respond with adjustments and changes to the charging process (e.g. back-up lead-acid batteries can be purchased for multi-shift operations). Our Selectiva 4.0 chargers offer an innovative solution for fast or opportunity charging of lead-acid batteries. The Power Charging Option supplies lead-acid batteries with energy in a short time and thus helps you to manage temporary workload peaks or the changeover to multi-shift operation.

As shift models become more intensive and battery charging, changing and maintenance becomes difficult and time consuming, Lithium-ion forklift trucks, batteries and chargers are recommended for a more efficient logistics operation.

For more information about our range of Lithium-ion battery chargers, visit our website.

Full support from the get-go

Having worked with many of our customers through their natural growth, we have gained insight into the best way to optimise a forklift fleet charging process.

We’re here to work with you from start to finish of your sustainable charging transition. We start with a full analysis of your charging infrastructure to offer you the best solution, plan your system, support installation and training, provide ongoing support either directly with us or through our network of Fronius Service Partners and, finally, support you to success.?

For more information about our chargers, visit?www.fronius.com/en-gb/uk/battery-charging-technology?or get in touch with myself or Andrew to find out how we can assist you.

Ross Adams | National Sales Director | +44(0)7580 076 988 | [email protected]

Andrew Wrigglesworth | Technical Sales Advisor | +44(0)7805 704 262 | [email protected]