Driven by the rise of e-commerce, molded by increased competition, and enabled by technological innovations, the modern warehouse has taken center-stage, handling more complex tasks than just simple storage. In this article, we’ll cover the main trends and challenges in warehousing that have caused this transformation. Then, we’ll explore the ways in which innovations – especially with respect to material handling equipment and Lithium-Ion Battery charging technology – provide effective solutions to these trends and challenges.
Significant progress has been made in the last few decades with displays and user interfaces, starting from simple analog meters and mechanical timers to the current variety of menus for precise control, display and reporting. Strong innovation in data storage has been made to make charger and battery history available to browse as needed in order to efficiently manage a fleet. Fleet management software and cloud based software is also vital to maximizing warehouse efficiency as it allows the operators to see the status of which batteries are losing charge. Improved data collection, application of precise controls and high efficiency now serve as the cornerstones for battery charger technology across the industry.
The purpose of a Industrial Li-ion battery charger is to charge the battery to keep the material handling equipment moving, maintain the battery to maximize its uptime and lifespan, and interact with battery devices to store battery information to help manage a fleet of batteries.
Li-ion batteries are particularly well suited to help warehouses adapt to these dual trends of reducing facility footprints while increasing reliance on specialized material handling equipment. For one, using Li-ion batteries eliminates the need for costly battery storage areas. This allows companies to repurpose their existing industrial battery warehouse space to accommodate more storage area, or eliminate future construction costs altogether. The root reason for this is that Li-ion batteries provide greater run times and faster-charging cycles than lead-acid industrial forklift batteries. Consequently, they do not have to be changed multiple times per shift, eliminating both the need for spare batteries and the space to store them.
One company that has benefited from this is a China-based dairy company. They were able to save $650,000 in construction costs for a new lead-acid battery storage space by switching their forklift fleet to run on Li-ion batteries. In addition to the space-saving advantage, Li-ion batteries also have the ability to work across a wide swath of specialized material handling equipment. In fact, BSLBATT lithium is a manufacturing and trading combo, specializing in Lithium batteries for over 10 years including all brands and models of lift trucks (Class I, II, and III), Ground Support Equipment, aerial lifts, and storage energy more. , has over 950 Li-ion battery models available to fit nearly any type of machine. Better yet, they fit within standard battery compartment sizes and connect to existing electrical systems, so there is no need for expensive modifications to accommodate them.
AGVs are electric vehicles and thus require batteries for power. And where lithium battery systems really shine is in their compatibility with AGVs and other automated equipment. There are multiple reasons for this. For one, Li-ion batteries have quick-charge capabilities, enabling longer operating hours without incurring the life-reducing effects of opportunity charging that is associated with lead-acid forklift batteries. In fact, lithium battery cycles can span up to 3,000 charges as opposed to 1,500 for lead-acid batteries. Additionally, using Li-ion power means having a no-maintenance battery system, eliminating the need for daily upkeep as is required with lead-acid batteries. And where problems do arise, an integrated battery management system can immediately alert facility operators so corrective measures can be taken.
Common measures include cell balance, volts per cell, electrolyte temperature and electrolyte level. A proposed new measure takes into account the electrolyte’s specific gravity, the ratio of the weight of the battery electrolyte as compared to an equal volume of water. It is the most accurate measure of state of charge.
Using the new specific gravity value and all other common measurements, the envisioned battery management system could actively manage the battery over its entire lifetime. Steps taken in managing a battery include charging using a specific gravity and managing equalization schedules, temperatures and the amount of recharge in opportunity charge applications.
Overcharging both reduces battery life and comes with higher energy costs. Having an accurate measurement of undercharge minimizes sulfation, the damage caused when large crystalline deposits build up inside the battery, reducing battery life, capacity and its ability to accept a charge. An accurate measurement of battery charge will optimize the frequency of charging, minimize costly battery replacements and take manufacturing and warehousing operations to a new level of efficiency.
The goal for advancing battery charging and management innovation is to develop the technology to the point where it is intelligent enough to require little to no supervision.
● We need battery management systems that:
● Make them last as long as possible.
● Ensure the most uptime.
● Use the least amount of power.
● Do not require a user to adjust settings throughout the battery’s life.
● Recover a fleet of existing batteries from a mismanaged condition.
● Constantly track battery conditions to make sure the charger terminates on target.
New battery management innovations could increase both uptime and battery life dramatically. Battery management systems with upgraded instrumentation could provide true state of charge for every charge cycle. Ultimately, the goal is less down time, less required maintenance, longer usage cycle and lower energy costs, which results in lower total cost of ownership.
The warehousing industry has experienced an upheaval in recent years. Emerging trends have placed unprecedented pressure on existing structures and solutions, forcing a change in the function and configuration of the modern warehouse. Much of this change has been enabled by emerging technologies, especially next-generation power systems like Innovate lithium-ion battery charging technology. For companies that need to keep up with the pace of modern commerce, adopting Li-ion technology solutions can be a major step forward.
