Industrial Power Solutions | Pallet Jacks Battery
Pallet Jacks Battery
Needs Analysis
- Extend continuous operation time to cover full shifts without battery swapping
- Implement opportunity charging capabilities to minimize downtime
- Enhance power output for consistent performance under varying load conditions
- Integrate smart features for fleet management and predictive maintenance
- Ensure durability and safety in demanding industrial environments
Battery Specifications
PowerLift Logistics required a custom battery solution meeting the following specifications:
- Dimension: Maximum 330mm x 172mm x 214mm to fit within compact pallet jack design
- Weight: Not exceeding 30 kg to maintain pallet jack maneuverability
- Voltage: 24V nominal
- Capacity: Minimum 200Ah, with a target of 250Ah for extended operation time
- Discharge Rating: Continuous discharge rate of 1C, with peak capability of 3C for 30 seconds to handle heavy loads and ramps
- Chemistry: Lithium Iron Phosphate (LiFePO4) for long cycle life, safety, and fast-charging capability
- BMS (Battery Management System):Advanced cell balancing with individual cell monitoring
- Bluetooth and Wi-Fi connectivity for remote diagnostics and fleet management
- Adaptive power management based on load and operational patterns
- Self-diagnostic capabilities with predictive maintenance alerts
- Certifications: UL 2271, IP65 rating for water and dust resistance
Solution Design:
- We developed an advanced battery solution for PowerLift Logistics:Utilized high-performance LiFePO4 cells with optimized energy density
- Implemented a compact, shock-resistant enclosure with integrated thermal management
- Integrated an AI-powered BMS for intelligent power distribution and usage analytics
- Developed a proprietary fast-charging system compatible with opportunity charging stations
- Implementation Process:Collaborated closely with PowerLift’s engineering team through multiple design iterations
- Conducted extensive field testing across various warehouse layouts and load scenarios
- Provided comprehensive support for integration with PowerLift’s fleet management software
Performance Data
- Operation time increased by 35%, from 8 hours to 10.8 hours on a single charge
- Charging time reduced by 60%, achieving 80% charge in just 1 hour
- Load handling performance improved by 25%, enabling consistent operation with heavier payloads
- Battery lifespan extended to over 3000 cycles, a 50% improvement over lead-acid alternatives
This custom battery solution has revolutionized our electric pallet jack capabilities. The extended operation time and opportunity charging have significantly reduced downtime in our customers' operations. The smart features and improved performance have set a new benchmark in the industry, enhancing productivity in material handling tasks.
