Lithium-Batterielösungen für Materialtransportgeräte und Robotik

Material handling equipment and robotics are used across warehouses, distribution centers, factories, logistics facilities, and automated production environments.

Equipment such as forklifts, electric walkie stackers, AGVs, AMRs, logistics robots, and inspection robots requires a battery system that matches its electrical, mechanical, communication, and operating requirements.

Lithium-ion batteries can be configured for different material handling and robotic applications. Depending on the equipment design, the battery pack may include lithium-ion or LiFePO4 cells, a Battery Management System (BMS), communication interfaces, protection components, connectors, and a customized enclosure.

For OEM equipment manufacturers, battery selection should begin with the equipment requirements rather than a standard battery model.

This guide explains how lithium battery packs can be designed for material handling equipment and robotics, including battery chemistry, voltage, capacity, current, BMS, communication, charging, mechanical integration, testing, and certification.

What Are Material Handling and Robotics Batteries?

Material handling and robotics batteries are rechargeable battery systems designed to supply electrical power to equipment used for transportation, lifting, automation, inspection, and warehouse operations.

Die Anwendungen umfassen:

• Elektro-Gabelstapler
• Electric walkie stackers
• Hubwagen
• AGVs
• AMRs
• Logistics robots
• Lagerroboter
• Inspektionsroboter
• Autonomous handling equipment
• Industrieroboter
• Cleaning robots
• Mobile platforms

Depending on the application, the battery may power:

• Traction motors
• Lifting systems
• Hydraulic systems
• Robotic actuators
• Controllers
• Sensoren
• Communication systems
• Anzeigen
• Sicherheitssysteme
• Computing equipment

The battery configuration should be matched to the equipment’s electrical architecture and operating profile.

---

Lithium-Ion Batteries for Material Handling Equipment

Lithium-ion batteries are used in material handling equipment where rechargeable electrical power is required for repeated operation.

A lithium battery system can be designed around:

• Erforderliche Spannung
• Akkukapazität
• Dauerstrom
• Spitzenstrom
• Betriebszeit
• Ladevorgaben
• Abmessungen der Batterie
• Kommunikationsprotokoll
• Umgebungsbedingungen

For industrial equipment, battery selection involves more than choosing an Ah rating.

The battery must work with the motor, controller, charger, BMS, mechanical structure, and other electrical components.

---

Lithium Battery Applications in Material Handling

Elektrostapler

Electric forklifts require battery systems for traction and lifting functions.

A custom lithium battery can be designed according to:

• Forklift voltage
• Motorleistung
• Betriebsstunden
• Anforderungen an die Belastung
• Charging schedule
• Battery compartment
• BMS-Anforderungen

Battery configurations may include LiFePO4 or other lithium-ion chemistries according to the application.

Electric Walkie Stackers

Electric walkie stackers are used for pallet transportation and lifting in warehouses and production environments.

A battery system can be customized according to:

• Spannung
• Kapazität
• Motor current
• Lifting current
• Abmessungen der Batterie
• Anschluss
• Ladegerät
• Kommunikationsschnittstelle

Smart BMS functions can also be integrated when battery information needs to be exchanged with the equipment controller.

Hubwagen

Electric pallet trucks use batteries for traction and lifting functions.

Battery design can consider:

• Compact installation space
• Operating cycle
• Spitzenstrom
• Ladehäufigkeit
• Gewicht der Batterie
• Connector configuration

A custom battery enclosure can be designed according to the pallet truck’s available installation space.

---

Lithium Batteries for AGV Systems

AGV stands for Automated Guided Vehicle.

AGVs are used for automated material transportation in factories and warehouses.

AGV battery systems may need to support:

• Repeated driving
• Automated charging
• Opportunitätskosten
• Long operating schedules
• BMS communication
• Fleet management systems

A custom AGV battery pack can include:

• LiFePO4-Zellen
• Intelligente BMS
• CAN-Kommunikation
• RS485-Kommunikation
• Kundenspezifische Steckverbinder
• Battery monitoring
• Customized enclosure

The battery configuration should be based on the AGV’s motor power, route, payload, operating cycle, and charging system.

---

Lithium Batteries for AMR Systems

AMR stands for Autonomous Mobile Robot.

AMRs are used for automated transportation and logistics tasks.

Compared with a basic mobile platform, an AMR may include additional electrical loads such as:

• Navigation sensors
• Kameras
• LiDAR
• Industrial computers
• Wireless communication
• Safety sensors
• Antriebsmotoren
• Steuerungssysteme

Therefore, the battery capacity calculation should include both the motion system and auxiliary electrical loads.

A battery pack for an AMR can be configured according to the robot’s:

• Betriebsstunden
• Durchschnittliche Leistungsaufnahme
• Peak power
• Charging schedule
• Nutzlast
• Reiseentfernung
• Battery compartment
• Kommunikationsanforderungen

---

Lithium Battery for Logistics Robots

Logistics robots are used for material transportation, sorting, warehouse operations, and internal logistics.

A logistics robot battery may need to provide power to:

• Antriebsmotoren
• Steuerungssysteme
• Sensoren
• Kommunikationsmodule
• Industrial computers
• Lifting mechanisms

Battery customization can include:

• Spannung
• Kapazität
• Zellkonfiguration
• BMS
• CAN
• RS485
• UART
• Anschluss
• Housing
• Befestigungskonstruktion

The battery can be designed according to the robot’s operating cycle and available installation space.

---

Lithium Battery for Inspection Robots

Inspection robots are used to monitor industrial facilities, warehouses, power systems, pipelines, infrastructure, and other environments.

Depending on the robot design, the battery may supply power to:

• Antriebsmotoren
• Kameras
• LiDAR
• Sensoren
• Industrial computers
• Communication systems
• Robotic mechanisms

Inspection robot batteries can be designed around the required operating time and equipment power consumption.

A smart BMS can provide battery information such as:

• Spannung
• Aktuell
• Temperatur
• SOC
• Fehlerstatus

Communication can be implemented through CAN, RS485, or another compatible interface.

---

Lithium Battery for Industrial Robots

Industrial robots can use battery systems when they operate on mobile platforms, autonomous systems, robotic carts, or other battery-powered equipment.

Battery requirements depend on:

• Motorleistung
• Robot payload
• Operating cycle
• Movement pattern
• Control system
• Auxiliary equipment
• Arbeitsumfeld

For mobile industrial robotics, battery design may include a customized enclosure and BMS communication system.

---

LiFePO4 Battery for Material Handling and Robotics

LiFePO4, or lithium iron phosphate, is a lithium-ion battery chemistry used in many industrial applications.

LiFePO4 characteristics include:

• Thermische Stabilität
• Stable discharge behavior
• Rechargeable operation
• Cycle characteristics suitable for repeated use
• Compatibility with BMS systems

A LiFePO4 battery pack can be configured according to the required voltage and capacity.

Zum Beispiel:

25.6V 100Ah LiFePO4 Battery

Nominal energy:

25.6V × 100Ah = 2,560Wh

or:

2.56kWh

The actual operating time depends on the equipment’s average power consumption, operating cycle, temperature, load, and battery utilization.

---

How to Calculate Battery Capacity

Battery energy can be estimated using:

Energie (Wh) = Spannung (V) × Kapazität (Ah)

Zum Beispiel:

48V × 100Ah = 4,800Wh

This represents approximately 4.8kWh of nominal energy.

For operating time:

Operating Time = Available Energy ÷ Average Power Consumption

For example, an equipment system with an average power consumption of 800W and a nominal battery energy of 4,800Wh has a theoretical operating time of:

4,800Wh ÷ 800W = 6 hours

Actual operating time depends on:

• Motorbetrieb
• Nutzlast
• Reiseentfernung
• Beschleunigung
• Lifting
• Auxiliary loads
• Temperatur
• Battery operating window
• Systemeffizienz

Therefore, capacity should be determined using actual equipment operating data.

---

Continuous and Peak Current

Battery sizing also requires current analysis.

Material handling equipment and robots may have different current requirements during:

• Start-up
• Beschleunigung
• Braking
• Lifting
• Drehen
• Ramp operation
• Motor loading
• Robotic movement

The battery pack should therefore be evaluated according to:

Dauerstrom

und

Spitzenstrom

The following components should also be matched to the electrical load:

• Batteriezellen
• BMS
• Fuse
• Busbar
• Cable
• Anschluss
• Protection components

---

Smart BMS for Industrial Battery Packs

A Battery Management System is an important component of a lithium battery pack.

Depending on the design, the BMS can monitor:

• Spannung einer einzelnen Zelle
• Pack-Spannung
• Ladestrom
• Entladestrom
• Cell temperature
• Batterietemperatur
• SOC
• SOH

Protection functions may include:

• Schutz vor Überladung
• Schutz vor Überentladung
• Überstromschutz
• Kurzschlussschutz
• Schutz vor Überhitzung
• Under-temperature protection

Cell balancing can also be included according to the battery design.

---

CAN Communication for Robotics and Material Handling

CAN communication is used in many industrial control systems.

A smart battery BMS with CAN can communicate battery information to an equipment controller.

Possible data includes:

• Batteriespannung
• Aktuell
• SOC
• Temperatur
• Ladezustand
• Fehlerinformationen
• Akkustatus

The BMS communication parameters and data format need to match the equipment controller.

For OEM projects, the communication protocol should be confirmed before BMS development.

---

RS485 and UART Communication

RS485 can also be used for industrial battery communication.

Depending on the equipment system, communication may use:

• RS485
• Modbus RTU
• UART
• CAN

The required interface depends on the equipment architecture.

For a custom battery project, the customer should provide the communication protocol or equipment communication specifications when available.

---

Battery Charging for Robotics and Material Handling Equipment

The charger is part of the complete battery system.

Important charging parameters include:

• Chemie der Batterie
• Nennspannung
• Ladespannung
• Ladestrom
• Charging profile
• Anschluss
• BMS communication
• Charging temperature range

For automated equipment, charging can be integrated into the operating process.

Charging methods may include:

• Standard charging
• Opportunitätskosten
• Geplantes Laden
• Automated charging

The charging method should be compatible with the battery, BMS, charger, and equipment control system.

---

Gelegenheitsladung

Opportunity charging allows equipment to receive charging during available idle periods.

It may be considered for:

• AGVs
• AMRs
• Elektrische Hubwagen
• Walkie stackers
• Lagerroboter
• Automated material handling systems

Charging may take place during:

• Breaks
• Shift changes
• Waiting periods
• Loading operations
• Automated docking

The battery manufacturer should define charging current and operating limits according to the battery design.

---

Automated Charging for AGV and AMR Batteries

AGV and AMR systems may use automated charging stations.

The battery system may need to communicate with the charging system to provide information such as:

• SOC
• Ladezustand
• Batterietemperatur
• Fehlerstatus
• Charging permission

The battery, BMS, charging station, and robot controller should be designed as a compatible system.

---

Custom Battery Dimensions

Industrial robots and material handling equipment often have limited battery installation space.

A custom battery pack can be designed according to:

• Länge
• Breite
• Höhe
• Befestigungslöcher
• Battery tray
• Anschlussposition
• Kabelauslass
• Handle
• Enclosure

Mechanical drawings or 3D models can be useful during the battery design process.

The battery should be securely mounted to handle expected vibration, acceleration, braking, and equipment movement.

---

Battery Enclosure Design

The battery enclosure provides mechanical protection for internal components.

Depending on the application, enclosure materials may include:

• ABS
• PC
• Aluminum
• Steel
• Other engineering materials

The enclosure design can consider:

• Mechanical protection
• Wärmeableitung
• Water protection
• Staubschutz
• Connector placement
• Kabelverlegung
• Mounting
• Service access

The final material and enclosure structure should be selected according to the application.

---

Environmental Requirements

Material handling equipment may operate in:

• Lagerhallen
• Fabriken
• Cold storage
• Vertriebszentren
• Outdoor logistics areas
• Industrial facilities

Environmental conditions may include:

• Staub
• Luftfeuchtigkeit
• Temperature changes
• Water exposure
• Vibration
• Mechanical impact

Battery design should consider the actual operating environment.

For applications requiring dust and water protection, an IP-rated enclosure can be evaluated.

The required IP rating should be determined according to the equipment environment and verified through appropriate testing.

---

Battery Safety Design

Battery safety should be considered throughout the entire development process.

Important areas include:

Zellauswahl

Cells should be evaluated according to:

• Kapazität
• Spannung
• Dauerstrom
• Spitzenstrom
• Zyklusvorgaben
• Temperaturbereich
• Manufacturer specifications

BMS

The BMS should be configured according to:

• Zellkonfiguration
• Spannung
• Aktuell
• Temperatur
• Protection limits
• Kommunikationsanforderungen

Electrical Protection

The battery may include:

• Fuse
• Protection circuit
• Busbar
• Insulation
• Rated connectors
• Appropriate cables

Thermal Management

Thermal design should consider:

• Zelltyp
• Aktuell
• Operating cycle
• Ambient temperature
• Enclosure
• Wärmeableitung

Mechanical Protection

The enclosure and mounting structure should protect the battery from expected mechanical conditions.

---

Custom Lithium Battery Development Process

A structured development process can help define battery requirements before production.

Step 1: Equipment Requirement Analysis

Collect:

• Equipment model
• Spannung
• Motorleistung
• Aktuell
• Betriebsstunden
• Battery compartment
• Ladegerät
• Kommunikationsprotokoll

Step 2: Operating Profile

Evaluate:

• Daily operating time
• Operating cycles
• Nutzlast
• Reiseentfernung
• Lifting frequency
• Lademöglichkeiten
• Ambient temperature

Step 3: Battery Chemistry

Evaluate:

• LiFePO4
• NMC
• Other lithium-ion chemistries

The chemistry should be selected according to the equipment requirements.

Step 4: Cell Selection

Evaluate:

• Cell capacity
• Spannung
• Aktuell
• Innerer Widerstand
• Cycle characteristics
• Temperature specifications
• Physical dimensions

Step 5: Battery Configuration

Determine:

• Series connection
• Parallel connection
• Nennspannung
• Kapazität
• Energie
• Current capability

Step 6: BMS Design

Define:

• Schutzparameter
• Current rating
• Temperatursensoren
• SOC
• SOH
• CAN
• RS485
• UART

Step 7: Mechanical Design

Develop:

• Enclosure
• Befestigungskonstruktion
• Anschluss
• Cable
• Kabelbaum
• Abmessungen der Batterie

Step 8: Prototype

Build a prototype for:

• Installation verification
• Elektrische Prüfungen
• Charging verification
• Kommunikationstests
• Runtime evaluation
• Temperature evaluation

Step 9: Validation

Complete the applicable:

• Electrical tests
• BMS tests
• Communication tests
• Environmental tests
• Mechanical tests

Step 10: Production

After validation, the battery design can move into production with defined quality control and inspection procedures.

---

Battery Testing

Testing should be defined according to the battery design and application.

Electrical Testing

• Prüfung der Kapazität
• Charge testing
• Discharge testing
• Spannungsprüfung
• Laufende Tests
• Prüfung des BMS-Schutzes

BMS Testing

• Schutz vor Überladung
• Schutz vor Überentladung
• Überstromschutz
• Kurzschlussschutz
• Temperaturschutz
• Zellausgleich

Communication Testing

• CAN
• RS485
• UART
• SOC communication
• Fault reporting
• Data transmission

Umweltprüfungen

Depending on the application:

• Prüfung bei hohen Temperaturen
• Prüfung bei niedrigen Temperaturen
• Temperature cycling
• Humidity testing
• Water protection testing
• Dust protection testing

Mechanical Testing

• Vibrationsprüfung
• Impact testing
• Prüfung von Steckverbindern
• Mounting testing
• Enclosure inspection

---

Zertifizierungen und Konformität

Lithium battery requirements depend on the battery design, application, transportation method, and target market.

For lithium batteries transported internationally, UN 38.3 is an important transportation testing requirement.

Depending on the product and destination market, applicable requirements may include:

• CE
• IEC-Normen
• UL-Normen
• RoHS
• EMV-Anforderungen
• Regional battery regulations

For products placed on the European market, applicable requirements under EU-Batterieverordnung (EU) 2023/1542 should also be evaluated.

Certification requirements should be considered during the product development stage.

---

What Information Is Required for a Custom Battery?

For an OEM or ODM battery project, the following information can help the engineering team define the battery system:

Additional information can include:

• Equipment datasheet
• Original battery label
• Charger datasheet
• Motor specifications
• Technische Daten des Controllers
• Battery compartment drawing
• Connector drawing
• Kommunikationsprotokoll
• 3D model
• Required certifications

---

How to Select a Lithium Battery Manufacturer

Selecting a battery manufacturer involves evaluating engineering capability, manufacturing processes, quality management, testing, and technical support.

Technische Kompetenz

The manufacturer should be able to evaluate:

• Chemie der Batterie
• Zellkonfiguration
• BMS
• Current requirements
• Kommunikation
• Kompatibilität mit Ladegeräten
• Mechanical structure
• Thermal requirements

Manufacturing Capability

Relevant production capabilities may include:

• Zellsortierung
• Schweißen
• PACK-Baugruppe
• BMS-Installation
• Batteriealterung
• Elektrische Prüfungen
• Funktionsprüfung
• Endkontrolle

Testing Capability

The manufacturer should have testing processes appropriate to the battery application.

These may include:

• Prüfung der Kapazität
• Alterungsprüfung
• BMS testing
• Temperaturprüfung
• Vibrationsprüfung
• Prüfung der Wasserdichtigkeit
• Kommunikationstests

Unterstützung bei der Zertifizierung

The manufacturer should be able to explain:

• Existing certification
• Applicable standards
• Testing requirements
• Dokumentation
• Transportation requirements

Certification claims should be supported by appropriate documentation.

---

OEM and ODM Lithium Battery Pack Solutions

OEM and ODM battery development allows equipment manufacturers to define battery specifications according to their products.

Customization can include:

Elektrotechnik

• Spannung
• Kapazität
• Aktuell
• Zellkonfiguration

BMS

• Schutzparameter
• SOC
• SOH
• CAN
• RS485
• UART

Mechanical

• Abmessungen
• Enclosure
• Mounting
• Anschluss
• Cable
• Kabelbaum

Aufladen

• Ladespannung
• Ladestrom
• Charging connector
• Kommunikation beim Laden

Branding

Depending on the project, OEM customization may include:

• Battery label
• Product identification
• Verpackung
• User documentation

---

About Our Lithium Battery Manufacturing Experience

Dongguan Yizhan Electronics Technology Co, Ltd. provides customized lithium battery PACK solutions for industrial and OEM applications.

Our battery development process can cover:

Requirement Analysis → Cell Selection → Battery Configuration → BMS Design → Mechanical Design → Prototype → Testing → Certification Evaluation → Production

Battery solutions can be developed for applications including:

• Elektro-Gabelstapler
• Walkie stackers
• Hubwagen
• AGVs
• AMRs
• Logistics robots
• Inspektionsroboter
• Industrieroboter
• Lagertechnik
• Other mobile industrial equipment

Depending on project requirements, battery packs can be configured with:

• LiFePO4-Zellen
• Lithium-Ionen-Zellen
• Intelligente BMS
• CAN-Kommunikation
• RS485-Kommunikation
• UART-Kommunikation
• Kundenspezifische Steckverbinder
• Custom wiring harnesses
• Custom enclosures
• Customized battery dimensions

The final battery configuration is determined according to the customer’s equipment specifications, operating conditions, and target market.

---

Why Battery Development Should Start With Equipment Requirements

A lithium battery is part of the equipment’s power system.

It interacts with:

• Motor
• Steuergerät
• Ladegerät
• BMS
• Sensoren
• Anzeige
• Communication system
• Safety system
• Mechanical structure

For this reason, battery development should begin with equipment requirements.

Early technical evaluation can help define:

• Spannung
• Kapazität
• Aktuell
• Abmessungen der Batterie
• BMS
• Kommunikation
• Ladegerät
• Anschluss
• Mounting
• Environmental requirements

This process provides a technical foundation for prototype development and production.

---

FAQ

What lithium battery is used for material handling equipment?

LiFePO4 and other lithium-ion chemistries can be evaluated for material handling equipment. The battery chemistry should be selected according to voltage, capacity, current, operating cycle, temperature, installation space, and equipment requirements.

Can lithium batteries be used in forklifts?

Yes. Lithium battery systems can be designed for electric forklifts according to the forklift’s electrical and mechanical requirements.

Can I use a lithium battery in an electric walkie stacker?

A lithium battery can be considered for an electric walkie stacker after evaluating voltage, charger, controller, current requirements, battery dimensions, BMS, and communication requirements.

What lithium battery is used for AGVs?

AGVs can use LiFePO4 or other lithium-ion battery configurations depending on their voltage, capacity, current, operating cycle, charging system, and installation space.

What battery does an AMR need?

An AMR battery should be sized according to the robot’s average power consumption, peak power, operating hours, payload, travel distance, auxiliary loads, and charging schedule.

Can a robot battery use CAN communication?

Yes. A smart BMS can use CAN communication when the battery and robot controller use compatible communication parameters and data formats.

Can the battery dimensions be customized?

Yes. Battery dimensions, enclosure, mounting structure, connector, cable length, and wiring can be customized according to the equipment.

Can the battery use LiFePO4 cells?

Yes. LiFePO4 cells can be used for many industrial battery applications. The final cell selection should be based on the equipment requirements and operating conditions.

Can lithium batteries support opportunity charging?

Lithium batteries can support opportunity charging when the battery, BMS, charger, and equipment are designed for this charging method.

What information is needed for a custom battery quote?

Useful information includes voltage, capacity, continuous current, peak current, operating time, charging requirements, battery dimensions, connector, communication protocol, operating temperature, equipment model, and target market.

---

Schlussfolgerung

Lithium batteries can be configured for a wide range of material handling equipment and robotics applications.

Dazu gehören:

Forklifts | Walkie Stackers | Pallet Trucks | AGVs | AMRs | Logistics Robots | Inspection Robots | Industrial Robots

The battery system should be designed according to:

Chemistry + Voltage + Capacity + Current + BMS + Communication + Charger + Dimensions + Environment + Safety + Certification

LiFePO4 is one battery chemistry that can be evaluated for industrial applications. Other lithium-ion chemistries may also be considered according to the equipment’s technical requirements.

For OEM and ODM projects, a custom lithium battery pack can integrate cell selection, battery configuration, smart BMS, communication, charger compatibility, mechanical design, testing, and certification evaluation.

A structured development process helps align the battery with the equipment’s electrical, mechanical, charging, communication, and operating requirements.

Custom lithium battery solutions can be developed according to your material handling equipment or robotics specifications.