AGV Battery

Needs Analysis

• Extend continuous operation time to cover full 24-hour shifts without battery swapping
• Implement opportunity charging capabilities to eliminate dedicated charging zones
• 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

AutoLogix Systems required a custom battery solution meeting the following specifications:

• Dimension: Maximum 800mm x 400mm x 200mm to fit within AGV’s compact design
• Weight: Not exceeding 250 kg to maintain AGV payload capacity
• Voltage: 48V nominal
• Capacity: Minimum 400Ah, with a target of 500Ah for extended operation time
• Discharge Rating: Continuous discharge rate of 1C, with peak capability of 2C for 60 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
• Wi-Fi and 4G connectivity for remote diagnostics and fleet management
• Adaptive power management based on load, route, and operational patterns
• Self-diagnostic capabilities with predictive maintenance alerts
• Certifications: UL 2580, IP65 rating for water and dust resistance

Solution Design

• We developed an advanced battery solution for AutoLogix Systems:Utilized high-performance LiFePO4 cells with optimized energy density
• Implemented a rugged, low-profile enclosure with integrated thermal management
• Integrated an AI-powered BMS for intelligent power distribution and usage analytics
• Developed a proprietary ultra-fast charging system compatible with opportunity charging stations

Implementation Process

• Collaborated closely with AutoLogix’s engineering team through multiple design iterations
• Conducted extensive field testing across various warehouse layouts and load scenarios
• Provided comprehensive support for integration with AutoLogix’s AGV fleet management software
• Performance Data:Operation time increased by 50%, from 16 hours to 24 hours on a single charge
• Charging time reduced by 75%, achieving 60% charge in just 15 minutes (opportunity charging)
• Load handling performance improved by 30%, enabling consistent operation with heavier payloads
• Battery lifespan extended to over 5000 cycles, doubling the industry standard

Conclusion

This case study showcases our expertise in creating custom battery solutions for the demanding automated material handling industry. By addressing AutoLogix Systems’ specific needs and exceeding their expectations, we’ve demonstrated our ability to deliver high-performance, reliable, and innovative power solutions that are driving the transition to more efficient and sustainable warehouse automation.