Lithium in forklifts

circuit

100 kW
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Hello. I am wondering if Lithium is worth it to be used in industrial forklifts. These have a large lead acid battery, usually in range of 20-53 kWh. I do have a lot of practice with lithium, however none with forklifts. Can someone lighten me up on these questions?
1. What is typical traction battery voltage?
2. Is regen used (both traction and lifting)?
3. How do they charge them? Do they require a separate well ventilated area? Is there a "closed system" to prevent gas leakage? Is there a charger onboard or do they use external charger? What power are these typically rated at?
4. How often do these lead acid batteries have to be serviced? How much does such service cost on average and what is the usual downtime?
5. What about charging in cold/heat? Any restrictions or additional measures required?
6. What is typical service life of a battery and at what point it is said that it is time for a new one?
7. What is typical lead battery price per 10kWh?
8. How do they measure the state of charge of the battery? Only by voltage? Are there any issues with unexpected power loss in practice? Or do they simply add a huge battery to make sure it lasts all day?
9. How big (kWh or Ah*V) of lead battery do you need for 5 ton forklift for a full busy day (no hills/regen)?
10. Is there a separate 12V system (battery?) or do they run it all on 48V, for example?
11. What power/current surges are to be expected?

Maybe I have forgotten about some important stuff, so will add those questions later. Of cause please feel free to add any info you feel needs to be said. Thanks!
 
I guess these forklift use the weight of these lead acid battery to counterbalance the weight they can carry o nthe front.
Doc
 
The carrying capacity of the forklift takes into account the weight of a full (stock) battery as a counterweight.

If you cut the battery weight in half, you're also increasing your tipping chances and decreasing your lift weight and height capacity.
 
48v is normal
600+ ah is normal

as above, they need the weight to hold the back of the truck down

chargers aren't traditionally on board, forklifts bounce like crazy (no suspension, solid tyres), chargers are fragile, and bulky
(most charges are wired directly into the mains, no plug etc... due to high power needed)

some new forklifts have an on board charger, but they're a bit smaller / lower power

45v 80amps is normal ish for external charger

in the uk, internal chargers are limited to just under 3kw - (240v 13amps, the max you tan take from a normal socket) - I'm not sure about the rest of the world


there's not a lot of point in anything other than lead batteries for forklifts... there weight is an advantage, and they have more than enough capacity for the vast majority of uses

plus, if the battery capacity isn't enough for what you need.... you could probably buy 2 leadacid forklifts for the price of the one lithium powered forklift
 
knighty said:
48v is normal
600+ ah is normal

as above, they need the weight to hold the back of the truck down

chargers aren't traditionally on board, forklifts bounce like crazy (no suspension, solid tyres), chargers are fragile, and bulky
(most charges are wired directly into the mains, no plug etc... due to high power needed)

some new forklifts have an on board charger, but they're a bit smaller / lower power

45v 80amps is normal ish for external charger

in the uk, internal chargers are limited to just under 3kw - (240v 13amps, the max you tan take from a normal socket) - I'm not sure about the rest of the world


there's not a lot of point in anything other than lead batteries for forklifts... there weight is an advantage, and they have more than enough capacity for the vast majority of uses

plus, if the battery capacity isn't enough for what you need.... you could probably buy 2 leadacid forklifts for the price of the one lithium powered forklift

I have not seen 13a plug tops used on forklifts. It's the wrong environment for them really. A 16a or 32a commando is more suitable.
 
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