2024 How Much Does a Forklift Battery Cost
Table of Contents
- 2024 How Much Does a Forklift Battery Cost
- The Real Expense of Lead-Acid Forklift Batteries
- The Real Cost of Lithium Forklift Batteries
- How to Evaluate Whether Lithium-Ion is Right for Your Fleet
- Steps to Convert Your Forklift Fleet to Lithium Batteries
- Conclusion
- The composition of solar lamps
- Main Components of Electric Vehicles-“Four Major Parts”
- What are the advantages of AGV
Forklift battery cost varies depending on the type and size of the battery. For lead-acid forklift batteries, the cost ranges from $2,000 to $6,000. In contrast, a lithium forklift battery typically costs between $17,000 and $20,000. However, MANLY Battery offers a more affordable range, with lithium forklift battery prices starting from $250 for smaller forklifts to $7,500 for larger models (excluding additional fees). Despite the higher initial investment, lithium batteries provide long-term savings through reduced maintenance, quicker charging, and longer lifespans. In this section, we will outline the steps to convert your forklift fleet to lithium-ion technology and maximize the benefits of this switch.
The Real Expense of Lead-Acid Forklift Batteries
1. Cost of Lead-Acid Batteries Over Time
The initial cost of a lead acid forklift battery might seem appealing due to its lower upfront price compared to lithium alternatives. However, the real expense accumulates over time due to several factors related to performance, labor, and operational efficiency. Lead-acid batteries typically require extensive maintenance, including regular watering, equalizing charges, and frequent monitoring. These processes consume both time and resources.
Each lead acid forklift battery can only operate for about 8 hours before needing a recharge, which takes approximately 16 hours to fully charge and cool down. For warehouses that run 24-hour operations, this means each forklift needs at least three batteries to function continuously. Managing these batteries requires labor-intensive tasks, such as switching out batteries, monitoring charging cycles, and performing maintenance, which leads to increased labor costs over time. The need to frequently stop operations to change batteries also reduces overall productivity, making the long-term cost of lead-acid batteries higher than initially perceived.
Over time, forklift battery replacement becomes inevitable as lead-acid batteries lose efficiency after around 1500 charge cycles, which generally occurs every 2-3 years. This frequent replacement cycle, combined with the need for multiple batteries per forklift, drives up costs significantly compared to alternatives like lithium forklift batteries, which have much longer lifespans and quicker charging times.
2. Storage Costs of Lead-Acid Batteries
One often overlooked cost associated with lead acid forklift battery use is the storage requirement. Lead-acid batteries are large and bulky, and warehouses must dedicate considerable space for both storage and charging stations. These batteries need a specific area for safe charging and cooling, often referred to as the battery room, which must meet strict guidelines to ensure safety.
The battery storage area must have proper ventilation to manage the gases emitted during the charging process, as well as the necessary infrastructure to handle these heavy batteries. This involves installing equipment such as overhead cranes or battery transfer carts to move the batteries safely. In addition to the physical space required, warehouses must invest in specialized monitoring systems to track battery conditions, charging cycles, and maintenance needs, all of which increase operational costs.
The storage area cannot be repurposed for other productive uses, meaning that valuable warehouse space is taken up solely for battery management. Over time, the inefficiency in space usage contributes to increased costs, particularly for businesses looking to maximize their warehouse floor for inventory or other operational needs.
3. Occupational Hazards and Risks
The use of lead acid forklift batteries also introduces significant occupational hazards. These batteries contain corrosive sulfuric acid and lead, both of which pose serious risks to workers. If a battery leaks or spills, it can cause severe chemical burns or environmental contamination. Handling these batteries requires specialized safety equipment and training to avoid accidents, adding to the operational cost.
Moreover, during the charging process, lead-acid batteries emit hydrogen gas, which is highly flammable. This creates a potential explosion risk if the gas accumulates in an inadequately ventilated space. Battery charging areas must be equipped with proper ventilation systems and safety measures to mitigate these risks. Even with these precautions, the possibility of accidents remains, which can lead to costly downtime, medical expenses, and potential fines if workplace safety regulations are not strictly followed.
In addition to physical risks, the labor required to maintain lead-acid batteries is another source of long-term cost. Workers must regularly water the batteries, clean corrosion from the terminals, and ensure that they are properly charged and cooled. These maintenance tasks take time away from other productive activities, adding hidden costs to the overall expense of using lead-acid batteries.
4. Replacement Expenses for Lead-Acid Batteries
Forklift battery replacement is a recurring cost that companies using lead-acid batteries must factor into their long-term budgeting. As mentioned earlier, these batteries typically last around 1500 charging cycles, which translates to about 2-3 years of usage under normal conditions. After this period, they need to be replaced, and this can become quite expensive when managing a large fleet of forklifts.
Each lead acid forklift battery is a significant investment, and purchasing multiple batteries every few years adds up. The cost of disposal also needs to be considered, as lead-acid batteries contain hazardous materials that require proper handling and recycling. Failing to dispose of them correctly can result in fines or environmental penalties, adding to the overall expense.
In contrast, lithium forklift batteries offer a much longer lifespan, often lasting up to 5000 cycles, which significantly reduces the frequency of replacement. While the upfront cost of lithium batteries is higher, the long-term savings in replacement expenses, maintenance, and labor make them a more cost-effective option for many businesses.
The Real Cost of Lithium Forklift Batteries
1. Lithium Forklift Battery Cost
When comparing the costs of lithium forklift batteries to lead-acid alternatives, the upfront price is significantly higher. On average, a lithium forklift battery costs between $17,000 and $20,000, which is about 2 to 2.5 times the price of a comparable lead-acid battery. This higher initial cost can be a deterrent for some businesses, but it’s essential to consider the long-term savings that come with this investment.
The primary areas where lithium forklift batteries save costs include energy efficiency, reduced downtime, minimal maintenance, and longer lifespan. Lithium forklift batteries are about 30% more energy-efficient than lead-acid batteries, and they can charge up to eight times faster. This means less electricity is used to power the same amount of work, leading to noticeable savings on energy bills over time. Additionally, the ability to charge the battery during breaks ensures continuous operation, which eliminates the need for multiple batteries per forklift, reducing overall battery investment.
Moreover, lithium forklift batteries can last two to four times longer than lead-acid batteries, meaning fewer replacements are needed over the years. This extended lifespan reduces the total number of batteries that need to be purchased, stored, and maintained, which further lowers overall operational costs. Although the initial lithium forklift battery cost is higher, the total cost of ownership becomes more favorable as savings accumulate in energy, labor, and replacements.
In addition to the general price range of lithium forklift batteries, MANLY Battery offers a more accessible option for businesses of all sizes. MANLY’s lithium forklift battery range is priced between $250 and $7,500, depending on the forklift model and battery capacity. This competitive pricing ensures that companies looking to switch to lithium technology have a broader range of options, from smaller forklifts requiring less power to larger industrial models. MANLY Battery’s products maintain high performance and durability while offering a more cost-effective solution in the lithium forklift battery market, making it easier for businesses to transition without the steep initial investment often associated with lithium technology.
Table of MANLY lithium Forklift Battery Cost (Partial list):
| Model No. | Specification | Unit price (USD) | Notes |
| ≤200 | |||
| MLP24150M | Battery Type: LiFePO4 Nominal Voltage:25.6V; Rated Capacity: 150AH Steel Case; Dimension: 640*245*220mm Cycle life: 5,000+ times; Lifespan: 15+ years design |
$750.00 | EXW price per battery excludes additional fees |
| MLP36200M | Battery Type: LiFePO4 Nominal Voltage: 38.4V; Rated Capacity: 200AH Steel Case; Dimension: 560*520*180mm Cycle life: 5,000+ times; Lifespan: 15+ years design |
$1,500.00 | |
| MLP72420M | Battery Type: LiFePO4 Nominal Voltage: 73.6V; Rated Capacity: 420AH Steel Case; Dimension: 700*600*550mm Cycle life: 5,000+ times; Lifespan: 15+ years design |
$6,000.00 |
Want more details or other models? Contact our customer service today!
2. Lithium Ion Forklift Battery Safety
One of the most significant advantages of lithium ion forklift batteries is their superior safety compared to lead-acid batteries. Lead-acid batteries require regular maintenance, including watering and acid handling, which exposes workers to hazardous chemicals like sulfuric acid. These batteries also emit hydrogen gas during charging, which can create an explosion risk if not properly ventilated. Furthermore, the risk of acid spills and exposure to harmful fumes poses additional safety concerns for workers.
In contrast, lithium ion forklift battery safety is much higher. Lithium forklift batteries are fully sealed and do not require watering, eliminating the need for workers to handle dangerous chemicals. They also do not produce harmful emissions during charging, which means that ventilation systems and hydrogen detectors are not necessary, reducing the overall safety equipment costs. This minimizes the risk of accidents and injuries, providing a safer work environment for warehouse staff. In addition, the lower maintenance needs of lithium ion batteries reduce the chance of human error during battery handling, further enhancing safety.
3. Lithium Ion Battery Advantages in Forklift Market
The lithium ion battery advantages in forklift market are numerous, and they provide a competitive edge for businesses looking to optimize their operations. One of the key benefits is the ability to support continuous operation. Lithium forklift batteries can be opportunity charged during short breaks, allowing for multi-shift operations without the need for battery swapping or extensive downtime. This is a game-changer for warehouses that operate 24/7, as it eliminates the need to purchase and manage multiple batteries per forklift.
Another significant advantage is the energy efficiency of lithium forklift batteries. While lead-acid batteries only convert about 75% of the energy consumed during charging into usable power, lithium forklift batteries can achieve up to 99% energy efficiency. This means that almost all the energy used to charge the battery is converted into work, resulting in lower electricity costs and a more environmentally friendly operation.
In cold storage environments, lithium forklift batteries perform exceptionally well. Lead-acid batteries can lose up to 35% of their capacity in freezing temperatures, leading to more frequent battery changes and higher energy consumption. Lithium forklift batteries, on the other hand, maintain their performance even in low temperatures, ensuring reliable operation and reducing the need for frequent battery replacements in cold storage facilities.
Furthermore, the longer lifespan of lithium forklift batteries—up to four times that of lead-acid batteries—means fewer battery replacements are needed over time. This reduces not only the cost of purchasing new batteries but also the logistical challenges of storing and maintaining multiple backup batteries. With less frequent replacements, companies can lower their operational costs and reduce downtime, ultimately increasing productivity and profitability.
4. Improved Productivity
The combination of faster charging times, longer battery life, and less frequent maintenance allows companies using lithium forklift batteries to experience a significant boost in productivity. Since these batteries can charge in as little as two hours, compared to the eight-hour charging cycle required for lead-acid batteries, forklifts spend less time out of commission and more time in operation.
Additionally, lithium forklift batteries do not suffer from performance degradation as they discharge, meaning that forklifts can operate at full capacity for longer periods. Lead-acid batteries, in contrast, gradually lose power as they discharge, which can slow down forklift performance and decrease overall productivity. With lithium forklift batteries, operators can rely on consistent performance throughout their shift, ensuring that tasks are completed efficiently.
The ability to opportunity charge during breaks also means that forklifts can run continuously across multiple shifts without the need for battery swapping or charging downtime. This uninterrupted operation enables warehouses to meet tight deadlines and increase throughput, ultimately enhancing their competitive advantage in the market.
5. Boosting Operational Competitiveness
Investing in lithium forklift batteries not only improves productivity and safety but also enhances a company’s long-term competitiveness. By reducing energy costs, minimizing downtime, and lowering maintenance needs, businesses can streamline their operations and reduce overall expenses. These operational improvements allow companies to allocate resources more effectively, focus on core business activities, and deliver products to customers more quickly.
Moreover, the environmental benefits of lithium forklift batteries—such as reduced energy consumption and fewer hazardous materials—align with growing corporate responsibility initiatives. Companies that adopt lithium forklift batteries can market themselves as environmentally conscious businesses, which is becoming increasingly important in today’s market. This can attract eco-conscious customers and strengthen the company’s reputation, further boosting its competitiveness.
In conclusion, while the initial lithium forklift battery cost may be higher than traditional lead-acid batteries, the long-term benefits far outweigh the upfront investment. From improved safety and energy efficiency to increased productivity and operational competitiveness, lithium forklift batteries provide a clear advantage for businesses looking to optimize their forklift operations and achieve long-term success.
How to Evaluate Whether Lithium-Ion is Right for Your Fleet
When assessing whether lithium forklift batteries are the right choice for your fleet, it’s essential to evaluate the specific needs of your operation. Efficiency, productivity, and cost savings are key factors that determine the success of any material handling operation. Lithium forklift batteries may offer significant advantages, but they are not always the best fit for every business. Below are several important factors to consider when deciding whether to switch to lithium-ion forklift batteries.
1. Multi-Shift Operations
One of the most significant benefits of using lithium forklift batteries is their ability to support multi-shift operations. In industries such as manufacturing, third-party logistics (3PL), and food processing, forklifts often need to run continuously to meet production demands. Lithium forklift batteries can be charged quickly and efficiently, often in just one to two hours, which is a huge improvement over lead-acid batteries that require eight hours to charge and another eight hours to cool.
For businesses that operate around the clock, lithium-ion technology eliminates the need for multiple batteries per forklift. Unlike lead-acid batteries, which need frequent battery swaps to keep forklifts running, lithium forklift batteries can be opportunity charged during breaks or idle times. This means that a single battery can power a forklift for an entire day without interruption, drastically reducing downtime and increasing overall productivity.
2. Cold Storage or Freezer Environments
Another critical factor to evaluate is whether your forklifts operate in cold storage or freezer environments. Lithium forklift batteries perform significantly better than lead-acid batteries in cold conditions. Lead-acid batteries can lose up to 35% of their capacity when operating in freezing temperatures, which leads to more frequent battery replacements and higher energy costs. On the other hand, lithium-ion batteries are much more resilient in low-temperature environments, maintaining their capacity and performance even in sub-zero conditions.
For businesses operating in cold storage or freezer facilities, this increased reliability can be a game-changer. Lithium forklift batteries also charge quickly in cold environments, ensuring that forklifts can stay operational without the need for extended downtime or battery swaps. This level of performance makes lithium-ion batteries the ideal choice for companies looking to optimize their cold storage operations.
3. Profit Margins and Cost Efficiency
If your business operates with tight profit margins, every cost-saving measure counts. While lithium forklift batteries come with a higher initial cost, the long-term savings they provide can make a significant difference to your bottom line. Lithium forklift batteries are up to 40% more energy-efficient than lead-acid batteries, which directly translates to lower energy bills. They are also 88% more efficient than diesel-powered forklifts, making them a more sustainable and cost-effective option.
In addition to energy savings, lithium-ion technology requires far less maintenance than lead-acid batteries. Lead-acid batteries must be regularly watered, cleaned, and monitored for performance, which adds labor costs and increases the risk of maintenance errors. In contrast, lithium forklift batteries are virtually maintenance-free, eliminating the need for watering or equalizing charges. This reduces the time and cost spent on battery upkeep, freeing up resources for other operational priorities.
4. Productivity Demands
The ability to quickly charge lithium forklift batteries and use them for longer periods makes them an excellent choice for businesses focused on maximizing productivity. Lead-acid batteries require lengthy charging and cooling periods, which can result in significant downtime. On the other hand, lithium-ion batteries can be charged during short breaks, allowing forklifts to remain operational across multiple shifts without the need for frequent battery changes.
Opportunity charging, which is a unique feature of lithium-ion batteries, allows forklifts to charge in as little as 15 to 30 minutes during breaks. This ensures that the forklift can continue operating without interruption, even in high-demand environments. For businesses where time is of the essence, this increase in operational efficiency can provide a competitive edge.
5. Return on Investment
For many businesses, the upfront cost of lithium forklift batteries is a significant consideration. However, it’s important to look beyond the initial investment and evaluate the total cost of ownership. Lithium-ion batteries typically have a lifespan of up to 3,000 cycles, compared to 1,500 cycles for lead-acid batteries. This means that lithium forklift batteries need to be replaced less frequently, reducing long-term replacement costs.
Additionally, the reduced maintenance requirements and energy savings from lithium-ion technology can result in a return on investment (ROI) within as little as 36 months for multi-shift operations. Even for single-shift operations, the ROI can be achieved within five years, making lithium forklift batteries a cost-effective long-term solution.
6. Safety and Environmental Impact
Safety is another important factor to consider when deciding whether lithium-ion batteries are right for your fleet. Lead-acid batteries contain hazardous chemicals like sulfuric acid, which pose safety risks during maintenance and charging. The need for regular watering and cleaning increases the likelihood of accidents, such as acid spills or exposure to harmful gases.
Lithium forklift batteries, on the other hand, are sealed units that require no maintenance and do not emit harmful gases. This eliminates the need for special ventilation systems or safety equipment, such as hydrogen detectors, in the charging area. Additionally, the absence of hazardous chemicals makes lithium-ion batteries a more environmentally friendly option, reducing your company’s environmental footprint and contributing to a safer work environment.
Steps to Convert Your Forklift Fleet to Lithium Batteries
Switching your forklift fleet to lithium forklift batteries can be a straightforward process that brings numerous benefits, including improved efficiency, lower maintenance, and enhanced performance. While the conversion from lead-acid to lithium forklift batteries is not overly complicated, there are specific steps and considerations to ensure a successful transition. Below are the key steps to converting your fleet to lithium-ion batteries.
1. Assess Your Current Forklift Fleet
The first step in converting your fleet to lithium forklift batteries is to assess your current forklift models and their power needs. Since forklifts come in various types and sizes, understanding the specific requirements of each model is crucial. Start by identifying the voltage and amp-hour (Ah) rating of the lead-acid batteries you are currently using. This will help you determine the appropriate lithium forklift battery replacement that matches the energy needs of your forklifts.
2. Choose the Right Lithium Battery
Once you have assessed your fleet, the next step is selecting the right lithium forklift battery for each forklift. It’s important to choose a battery with the same voltage as your current lead-acid battery to ensure compatibility with the forklift’s electrical system. However, one of the advantages of lithium-ion technology is that it offers a wider range of amp-hour capacities, allowing you to choose a battery that better suits the energy needs of each forklift in your fleet.
Ensure that the battery capacity (measured in Ah) is sufficient for your operational requirements. Forklifts that run continuously or on multi-shift operations may require higher-capacity batteries to maximize runtime and reduce the need for frequent charging.
3. Consider Weight and Balance
Another critical consideration when converting to lithium forklift batteries is the weight difference between lead-acid and lithium-ion batteries. Lithium forklift batteries are typically much lighter than their lead-acid counterparts. For counterbalance forklifts, where the battery acts as part of the counterweight, this reduction in weight can affect the forklift’s stability and load-carrying capacity.
To compensate for the lighter weight of lithium-ion batteries, you may need to add ballast or additional counterweight to the forklift. This will ensure that the forklift maintains its rated load-carrying capacity and operates safely under normal working conditions.
4. Upgrade or Adjust Charging Equipment
Converting to lithium forklift batteries may also require changes to your charging infrastructure. While lithium-ion batteries charge faster than lead-acid batteries and can be opportunity charged during breaks, you need to ensure that your current chargers are compatible with lithium-ion technology. Most lithium forklift batteries require chargers designed specifically for lithium batteries, as they use different charging algorithms to optimize battery life and performance.
Additionally, it’s important to ensure that the charging stations are equipped with battery monitoring systems to track battery health, charge cycles, and performance. These systems help prevent overcharging or undercharging, ensuring that the batteries remain in optimal condition for longer.
5. Train Operators on Opportunity Charging
To maximize the benefits of switching to lithium forklift batteries, it’s essential to train your forklift operators on proper charging practices. One of the biggest advantages of lithium-ion batteries is their ability to be charged during short breaks without reducing the overall lifespan of the battery. This is known as opportunity charging.
Encourage your operators to take advantage of opportunity charging whenever the forklifts are idle for a few minutes or during scheduled breaks. Unlike lead-acid batteries, which degrade if charged too frequently, lithium forklift batteries can handle frequent partial charges without negatively affecting their performance or longevity. This practice ensures that your forklifts are always ready for operation, reducing downtime and increasing productivity.
6. Install Monitoring and Safety Systems
When converting to lithium forklift batteries, it’s crucial to install battery monitoring systems that can provide real-time data on battery health, charge levels, and performance. Lithium-ion batteries require precise voltage and current management to prevent overcharging or deep discharging, both of which can damage the battery.
Some monitoring systems rely on voltage-based measurements, which may not provide accurate readings for lithium forklift batteries. Instead, use shunt-based monitoring systems that track amp-hour consumption and provide more reliable data for lithium-ion batteries. This will help you maintain the batteries in peak condition and prevent unexpected failures.
7. Evaluate the Total Cost of Conversion
Although lithium forklift batteries come with a higher upfront cost compared to lead-acid batteries, the long-term savings in energy, maintenance, and replacement costs can make the investment worthwhile. It’s important to evaluate the total cost of conversion, including the cost of the batteries, potential modifications to the forklifts, and any necessary upgrades to the charging infrastructure.
In most cases, businesses see a return on investment (ROI) within 36 months, especially in high-demand, multi-shift operations. For single-shift operations, the ROI may take longer, but the lower maintenance costs and increased productivity make the investment in lithium forklift batteries a smart long-term decision.
8. Consider Future Expansion
When converting your fleet to lithium forklift batteries, it’s worth considering the scalability of your operations. Lithium-ion technology is adaptable and can support the future growth of your business. If you anticipate expanding your forklift fleet or increasing operational hours, lithium forklift batteries offer the flexibility to scale up without requiring additional batteries or significant infrastructure changes. The ability to quickly charge and opportunity charge lithium-ion batteries ensures that they can keep up with growing demands.
Conclusion
Switching to lithium forklift batteries involves more than just replacing old batteries. By following the proper steps—evaluating fleet needs, choosing the right battery, updating charging equipment, and training staff—businesses can ensure a smooth transition and enjoy the benefits of lower maintenance, increased productivity, and long-term cost savings. With the ability to opportunity charge and reduced downtime, lithium forklift batteries provide a competitive edge in today’s demanding material handling environments.
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With the development and progress of solar photovoltaic technology, it was first applied to lighting fixtures in civil applications. In recent years, due to the dual advantages of environmental protection and energy saving, solar garden lights, solar lawn lights and solar street lights have gradually been applied Form a scale.
In the design of solar lighting lamps, many factors are involved, such as light source, solar battery system, battery charging and discharging control, and any problem in any link will cause product defects.
Solar lamps are composed of the following five parts
1. Solar panels
2. Charge and discharge controller
3. Battery
4. Load
5. Lamp shell
Commonly known as the “four major pieces” that make up an electric vehicle refer to the electric vehicle battery, motor, controller and charger. The following is an introduction to the functions, structure and functions of the “Four Major Items”:
One: Electric vehicle battery: It is the power source of electric vehicle, the energy carrier, used to drive the motor, the voltage of the electric vehicle battery determines the working voltage of the vehicle, and the battery capacity of the electric vehicle is directly proportional to the continuous journey of the vehicle.
The structure of lead-acid electric vehicle batteries commonly used in electric vehicles is mainly composed of electric vehicle battery shells, positive plates, negative plates, separators, electrolytes, terminals, sealants, safety valves and other components.
The types of electric vehicle batteries can be divided into: lithium-ion electric vehicle batteries, nickel-metal hydride electric vehicle batteries, gel electric vehicle batteries and maintenance-free lead-acid electric vehicle batteries. Among them, gel electric vehicle batteries and lead-acid electric vehicle batteries are commonly used.
According to the voltage, it can be divided into 6V, 12V, 24V, 36V, 48V, 60V, 64V, etc. The most commonly used electric vehicle is 48V.
According to the capacity specifications, it can be divided into: 10AH, 12AH, 17AH, 20AH, 22AH, etc. 12AH and 20AH storage battery batteries are commonly used in electric vehicles.
Two: Motor: Converts the chemical energy of the electric vehicle battery into mechanical energy, and converts the rotational energy into mechanical traction, so that the wheels rotate. The working voltage of the motor is inversely proportional to the working current, and the power of the motor is proportional to the climbing ability.
According to the way of energization, it can be divided into brush motor and brushless motor:
A: Brushed motors are composed of iron core windings, magnetic steel sheets, carbon brushes, carbon brush holders, commutators, etc. The regular operation effect is achieved by the exchange of contact between the carbon brushes and the commutator.
B: The brushless motor is composed of iron core windings, magnetic steel sheets, Hall elements, etc. It relies on Hall (dielectric degree angle) commutation to achieve regular operation.
According to the structure, the motors can be divided into: brushless and toothless, brushless and toothless, brushless and toothed, and brushed and toothed, etc. The most commonly used is brushless and toothless motors.
According to the working voltage, it can be divided into: 12V, 24V, 36V, 48V, 60V, 64V, etc. The most commonly used is the 48V motor.
According to the power, it can be divided into: 180W, 250W, 350W, 500W, 800W, 1000W, etc. The most commonly used are 350W and 500W motors.
Three: Controller: Control the output current of the electric vehicle battery, the voltage and then achieve the control of the motor speed and power, that is, the speed of the entire vehicle, to achieve the effect of controlling the entire vehicle. The main functions include stepless speed regulation, brake power failure, current limit protection, undervoltage protection, speed limit, speed display, 1:1 power assist, etc.
According to the difference of function and structure, it can be divided into two types: brush controller and brushless controller.
According to the working voltage, it can be divided into: 24V, 36V, 48V, 60V, 64V, etc. The most commonly used is the 48V controller.
According to the output power, it can be divided into: 180W, 250W, 350W, 500W, 800W, etc. The most commonly used controllers are 350W and 500W.
Four: Charger: It is a device that supplements the energy of the electric vehicle battery to charge the electric vehicle battery. It can convert the mains electricity into direct current and control its current and voltage to charge the electric vehicle battery and store it.
The charger is mainly composed of rectifier and filter, high voltage switch, voltage exchange and electric control. The working state has three stages: constant current, constant voltage and floating charge.
A: Constant current depends on the type of electric vehicle battery;
B: Constant voltage is determined according to the standard of electric vehicle battery. Conventionally, the single-cell voltage is 14.7V—14.8V.
C:Floating charge is determined according to the standard of electric vehicle battery, and the conventional single-cell voltage is 13.8V-14V.
Advantages of AGV:
(1) High degree of automation;
It is controlled by computer, electronic control equipment, laser reflector, etc.
When auxiliary materials are needed in a certain part of the workshop, the staff enters relevant information into the computer terminal, and the computer terminal sends the information to the central control room. Professional technicians issue instructions to the computer. With the cooperation of electronic control equipment, this The instruction is finally accepted and executed by the AGV-send the auxiliary materials to the corresponding place.
(2) Charging automation;
When the power of the AGV car is about to run out, it will send a request instruction to the system to request charging (general technicians will set a value in advance), and automatically go to the charging place after the system allows it to “queue” for charging.
In addition, the battery life of the AGV trolley is very long (more than 10 years), and it can work for about 4 hours per 15 minutes of charging.
(3) Beautiful, improve the viewing degree, thereby enhancing the image of the enterprise.
(4) Convenience and reduced floor space; the AGV trolley in the production workshop can shuttle back and forth in each workshop.
In the early days, AGV trolleys could only travel in one direction during automatic operation, so the applicable environment was limited. In order to meet the requirements of industrial production, in recent years, there have been AGV products in foreign countries that can move forward and backward or even travel, forward, reverse, sideways and rotate in all directions during automatic operation. These achievements are attributed to the progress of the walking mechanism.
1. Two-wheel differential traveling mechanism This traveling mechanism has two traveling driving wheels symmetrically arranged on the front and rear centerline, and two supporting wheels are arranged at the vertices of an isosceles triangle with the fulcrum of the two traveling wheels as the base. The trolley relies on both sides of the driving wheel to steer differentially, so there is no need to set a steering wheel. The trolley has simple structure, reliable work and low cost. In the automatic running state, the trolley can move forward and backward, and can make vertical turns with good maneuverability. Compared with the four-wheel walking mechanism trolley with steering wheels, the trolley can be made smaller due to the omission of the steering wheel, which not only saves two driving motors but also saves space. In recent years, the trolley of this kind of organization has been widely used. In order to improve the lateral stability of the car body when driving, the two-wheel differential four-wheel walking mechanism can be improved as follows. The supporting wheels are increased from the original two to four and arranged at the four corners of the chassis of the trolley.
2. Three-wheel walking mechanism The three wheels of the AGV trolley of the three-wheel walking mechanism are respectively arranged on the three vertices of an isosceles triangle. The front wheel is both a steering wheel and a walking driving wheel. The two wheels behind are unpowered supporting wheels. The AGV trolley of the three-wheel traveling mechanism is simple in structure, easy to control, reliable in work, and low in cost. When the car is manual, it can forward, reverse and turn automatically. It can only drive in one direction. When turning, the trajectory of the rear wheel’s midpoint deviates from the track of the guide wire and presents a trailing line.
3. Four-wheel walking mechanism with steering wheel The four-wheel walking mechanism with steering wheel is evolved on the basis of three-wheel walking mechanism, which is equivalent to combining two tricycles together. The two supporting wheels are symmetrically arranged on the center line of the front and rear of the trolley. The front and rear wheels are respectively arranged symmetrically at the vertices of an isosceles triangle with the fulcrums of the two supporting wheels as the base. The front and rear wheels are both steering wheels and walking driving wheels. This kind of AGV trolley can travel in all directions under automatic operation. When turning, the front and rear wheels can track the trajectory of the guide wire. The maneuverability is better than that of the tricycle. It is suitable for narrow aisle work environment.
4. Other forms of walking mechanism In recent years, foreign companies have continuously researched new walking mechanisms. Among them, the symbolic one belongs to the walking organization of Sweden’s Mackanham Company. The running mechanism is novel in design and compact in mechanism. Four driving wheels are arranged on the four corners of the chassis in an articulated form. When running, the steering and speed of the four wheels are controlled separately, and the speed vector synthesis principle is used to realize driving. Later, Japan’s Mitsui Co., Ltd. cooperated with McCannham Company to make improvements on the original basis and launched the Mitsui Mackanham Wheel System, which has improved its performance. This AGV trolley can realize all-round driving.
With the rapid development of logistics systems, the scope of application of AGV is also expanding. AGV systems are researching and designing an unmanned car system solution based on electromagnetic navigation. Through actual hardware experiments, the system can meet the expected design requirements and can be widely used In the fields of industry, military, transportation, electronics, etc., it has good environmental adaptability, strong anti-jamming ability and target recognition ability.
