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The Lithium-ION Battery Revolution in Material Handling
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Lithium-ION (Li-ION) technology has proven its worth in everyday use – from portable devices to automotive applications.
For forklifts and warehouse equipment, the technology offers a whole series of advantages over lead-acid batteries, with a growing number of ‘traditional’ electric forklift batteries being replaced with Li-ION versions while new machines are designed exclusively for the new intelligent battery options.
Materials handling equipment needs to be constantly available while also remaining safe and cost-effective to operate at all times.
In addition to the benefits of battery-electric equipment in general, such as reduced emissions, increased energy efficiency and avoiding the need to store dangerous fuels, Li-ION batteries bring further advantages because they can be charged quickly. This rapid charge capability, combined with higher energy density and high overall system efficiency, allows the batteries to provide up to 30% more energy than lead-acid.
Furthermore, the batteries suffer no loss of performance, even when the charge is low.
Conventional lead-acid batteries incur a whole host of maintenance and handling costs which are completely eliminated with Li-ION batteries. These include, for example, the cost of a second battery and labour costs for replenishing the lead-acid batteries with water and replacing these batteries.
In addition, Li-ION battery fleets do not require the complex charging infrastructure associated with lead-acid. Chargers can be flexibly set up at waypoints such as near break areas or in the immediate vicinity of the application area to save driving time.
With a renewed corporate focus on safety, it is important to note that Li-ION technology offers the highest level of driver and vehicle safety.
Li-ION batteries do not contain hydrogen, eliminating a significant chemical fume risk associated with lead-acid batteries.
Meanwhile, the elimination of battery replacement and maintenance removes the risk of injury associated with heavy lifting and chemical exposure.
To ensure that Li-ION batteries are protected, even in extreme situations, Linde encases them in a robust compartment and subjects them to crash tests of the maximum load.
Linde's Li-ION batteries meet all sustainability requirements, making their operation completely emission-free.
Linde’s environmental commitment spans the entire life of the battery, from production where fewer pollutants are released than for lead-acid batteries, to ensuring their longevity. Li-ION batteries enjoy a longer lifecycle than lead-acid batteries, meaning they don’t have to be replaced as often, resulting in a higher conservation of environmental resources.
Finally, the use of Li-ION-powered forklifts and warehouse equipment makes any application significantly more energy-efficient, resulting in the same overall output being achieved with less energy.
Batteries have evolved far beyond boxes that supply charge. Today’s batteries are equipped with micro-computers that control all operations at cell, module and battery level.
Battery management ensures optimum battery usage by constantly monitoring and coordinating vehicle functions, charging processes and the battery system.
This prevents damage caused by overpressure, overheating, over-charging or deep discharge.
In addition, truck control and battery management are optimally aligned, for example through the CANbus interface, which enables systems to communicate with each other. The battery system therefore balances peak loads, while simultaneously providing sufficient energy. This protects the battery and prolongs its operating life.
Li-ION provides a route to improved productivity, safety and environmental protection, and there are three major ways end-users can adopt the technology.
Firstly, there are a number of aftermarket replacement batteries which can be substituted for the original lead-acid cells that were supplied with the equipment. This may be the most cost-effective solution for some, but it fails to take full advantage of the capabilities of the latest Li-ION advances.
More benefit can be derived from choosing the Li-ION power option when purchasing new equipment. Linde, for example, offers a Li-ION version of every truck in its electric counterbalance range in Australia – all the way up to 18 tonnes. At the same time, most of the Linde warehouse and reach truck models also have a Li-ION option.
Finally, fleet operators might consider made-for-Lithium solutions – vehicles specifically designed around Li-ION cells and designed to maximise the benefits of the technology. In models like Linde’s X series, the battery cells are fully integrated into the forklift. Rather than being limited to a large single box, the cells can be distributed around the truck for maximum ergonomics. Furthermore, the batteries are optimised for the onboard battery management systems, making the most of the high-tech monitoring and performance management.
Li-ION is a mature technology that has become prevalent across industrial applications and it is improving efficiency and safety in materials handling at sites around the world.
If you’re committed to safe, environmentally secure and efficient operations, it is certainly time to explore the benefits of this new technology when updating or upgrading your fleet.
You can learn more about this innovative technology by visiting our Lithium-ION page.
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