FORKLIFTS & LIFTING EQUIPMENT – BATTERY MANAGEMENT
By Adam Offord
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Forklift trucks that run on electricity are common throughout industry.
So, what operational and maintenance-related advice and products are out
there for users looking to get the most out of their batteries?
Forklift truck (FLT) power options
typically fall into three categories
– diesel, gas (LPG), and electric.
Internal combustion engine
trucks are good for intensive
work, as they are easy to refuel, but so too
loud and limited to work outdoors. Gaspowered
FLTs, meanwhile, typically have
a low purchasing cost and can be used
both indoors and outdoors, but refuelling
requires more effort and experience.
The electric truck, on the other hand,
can also work indoors and outdoors, whilst
producing zero emissions and being easier
to handle. A downside to electric, perhaps,
is that batteries deplete and need charging
up, among other maintenance needs.
Therefore, if you’re an operator in charge
of an electric truck, knowing different
battery management techniques to get
the most out of the ‘workhorse’ could
mean the difference between job well
done and job incomplete.
Luckily, FLT trade associations and
manufacturers have a range of tips
and advice when it comes to battery
management, while different products
have been placed on the market to give
operators a helping hand.
TRADE ASSOCIATION ADVICE
The British Industrial Truck Association
(BITA) is a UK trade association for
FLT manufacturers and suppliers, and
suppliers of associated components and
services. Technical manager David Goss
(pictured inset, right) says that, first of
all, it is important to recognise that there
are two distinct battery technologies for
materials handling equipment – lithiumion
(Li-ion) and lead-acid (PbA) – and their
management requirements are different.
Lithium-ion batteries are virtually
maintenance free, thanks partly to a
sophisticated battery management
system (BMS) that monitors and optimises
battery condition, he explains. Although
the capital cost of Li-ion is comparatively
high, this should be considered against the
substantial benefits available:
● Energy efficiency is high during
charging, discharging and when recovering
energy, such as when the truck is braking;
● Where two-or three-shift usage
is envisaged, very rapid opportunity
charging, taking place during short periods
such as operator breaks, removes the
necessity for battery change-out between
on-truck use and a charging station.
“Be aware, however, that the power
supply requirement for fast charge is
higher, in direct proportion to the time
saved,” says Goss. “The lithium-ion
chemistry used on materials handling
equipment is different from that used
in the automotive industry. This means
that the batteries are much more stable.
However, irreversible damage can occur
to the cells if the charge is permitted to fall
below the critical undervoltage limit.
“All batteries suffer at temperature
18 www.operationsengineer.org.uk June 2019
/www.operationsengineer.org.uk