Logistics robots are increasingly used for material transportation, warehouse operations, production-line logistics, sorting, and automated handling.

These robots depend on a reliable power system to operate drive motors, controllers, sensors, industrial computers, communication modules, lifting mechanisms, and safety systems.

A logistics robot battery is therefore more than a group of lithium cells. It is an integrated power system that may include battery cells, a Battery Management System (BMS), protection components, temperature sensors, busbars, connectors, wiring harnesses, and a custom enclosure.

For an OEM logistics robot manufacturer, battery selection should be based on the complete equipment requirements. Voltage and capacity are important, but current, operating cycle, charging method, communication protocol, dimensions, temperature, and mechanical installation also need to be evaluated.

This guide explains the engineering considerations involved in selecting and customizing lithium battery packs for logistics robots.

What Is a Logistics Robot Battery?

A logistics robot battery is a rechargeable battery pack designed to provide electrical power to robots used in warehouses, factories, distribution centers, and internal logistics systems.

Depending on the robot architecture, the battery can supply power to:

• Antriebsmotoren
• Lifting motors
• Motor controllers
• Industrial computers
• LiDAR
• Kameras
• Navigation sensors
• Safety sensors
• Wireless communication systems
• Steuerungssysteme
• Displays and indicators

Different logistics robots have different power requirements.

For example, a mobile transport robot may primarily require power for traction, while a robot with lifting functions may have additional peak power requirements.

The battery configuration should therefore be developed according to the robot’s actual operating profile.

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Lithium Battery Applications for Logistics Robots

Lithium battery packs can be designed for several types of automated logistics equipment.

Warehouse Robots

Warehouse robots can use lithium batteries for transportation, sorting, picking assistance, and internal material movement.

AGVs

Automated Guided Vehicles use battery power for driving, control systems, sensors, and communication.

AMRs

Autonomous Mobile Robots may require power for drive motors, navigation systems, LiDAR, cameras, computers, and wireless communication.

Automated Handling Robots

Robotic handling platforms may require additional power for lifting or material handling mechanisms.

Mobile Inspection Robots

Inspection robots may use battery power for movement, cameras, sensors, computers, and communication systems.

Each application requires a battery configuration based on its own electrical and mechanical specifications.

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LiFePO4 Battery for Logistics Robots

LiFePO4, also known as lithium iron phosphate or LFP, is a lithium-ion battery chemistry that can be considered for industrial robotic applications.

LiFePO4 battery systems have characteristics including:

• Stable electrochemical behavior
• Thermische Stabilität
• Rechargeable operation
• Suitability for repeated charge and discharge
• Compatibility with BMS protection systems

The battery configuration can be customized according to the required voltage and capacity.

For example, a 25.6V 100Ah LiFePO4 battery has a nominal energy of:

25.6V × 100Ah = 2,560Wh

This equals approximately:

2.56kWh

The actual usable energy depends on the battery operating window, load profile, temperature, BMS settings, and system efficiency.

Other lithium-ion chemistries may also be evaluated depending on the robot’s requirements.

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How to Calculate Logistics Robot Battery Capacity

Battery capacity should be calculated from the robot’s energy requirements rather than selected only from the motor rating.

The basic formula is:

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

Zum Beispiel:

48V × 50Ah = 2,400Wh

The nominal battery energy is approximately 2.4kWh.

Estimated operating time can be calculated using:

Operating Time (h) = Available Energy (Wh) ÷ Average Power Consumption (W)

If the robot consumes an average of 600W:

2,400Wh ÷ 600W = 4 hours

This is a theoretical calculation.

Actual operating time can be affected by:

• Nutzlast
• Reiseentfernung
• Driving speed
• Beschleunigung
• Braking
• Motoreffizienz
• Floor conditions
• Lifting operations
• Sensor consumption
• Computer consumption
• Ambient temperature
• Battery operating window
• Charging strategy

For an OEM project, actual operating data should be used when available.

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Average Power and Peak Power Requirements

A logistics robot does not necessarily consume the same amount of power throughout its operating cycle.

Power demand may increase during:

• Motor startup
• Beschleunigung
• Drehen
• Ramp operation
• Heavy-load transportation
• Lifting
• Rapid movement
• System startup

The battery should therefore be evaluated using both average current und peak current.

Continuous Current

Continuous current refers to the current the battery needs to provide during normal operation.

Peak Current

Peak current refers to short-duration current requirements that may occur during motor startup, acceleration, lifting, or other high-load events.

The following components should be evaluated together:

• Batteriezellen
• BMS
• Fuse
• Busbars
• Cables
• Steckverbinder

The BMS current rating should also be compatible with the robot’s operating requirements.

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Smart BMS for Logistics Robot Battery Packs

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

A smart BMS can monitor and manage battery operating conditions.

Depending on the BMS design, monitoring functions can include:

• Spannung einer einzelnen Zelle
• Gesamtspannung der Batterie
• Ladestrom
• Entladestrom
• Batterietemperatur
• Cell temperature
• Ladezustand (State of Charge, SOC)
• Gesundheitszustand (SOH)

Protection functions may include:

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

Cell balancing can also be implemented according to the battery configuration.

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CAN Communication for Logistics Robot Batteries

Many industrial robots use communication between the battery and the main controller.

CAN communication can allow the BMS to transmit battery information such as:

• Batteriespannung
• Aktuell
• SOC
• Temperatur
• Ladezustand
• Fehlerstatus
• Alarm information

For an OEM logistics robot project, the communication protocol should be defined during the engineering stage.

The BMS needs to use communication parameters and data formats that are compatible with the robot controller.

If available, the customer can provide:

• CAN protocol
• CAN database file
• CAN ID information
• Data format
• Fault codes
• SOC requirements

This information can be used when configuring or developing the smart BMS.

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RS485 and UART Communication

Some logistics robots use RS485 or UART instead of CAN.

Possible battery communication interfaces include:

• CAN
• RS485
• UART
• Modbus RTU

The appropriate communication interface depends on the robot’s control architecture.

For customized battery development, communication requirements may include:

• Baud rate
• Address
• Data format
• Register information
• Communication commands
• Fault information
• SOC information

Communication testing should be completed during the prototype validation stage.

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Battery Charging for Logistics Robots

The charger should be compatible with the battery chemistry and electrical configuration.

Important charging parameters include:

• Chemie der Batterie
• Nennspannung
• Ladespannung
• Ladestrom
• Charging profile
• Ladegerätetyp
• Anschluss
• BMS-Anforderungen
• Kommunikationsanforderungen

For a custom battery project, the charger should be evaluated together with the battery.

A mismatch between the charger and battery specifications can affect charging performance and battery protection.

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Charging Methods for Logistics Robots

Logistics robots can use different charging strategies depending on their operating schedule.

Standard-Ladung

The robot returns to a designated charging area after completing an operating cycle.

This approach can be used when the robot has sufficient operating time between charging sessions.

Gelegenheitsladung

The robot receives charging during idle periods.

Potential charging periods include:

• Breaks
• Waiting periods
• Shift changes
• Low-demand periods
• Automated docking

The battery should be designed according to the required charging current and charging frequency.

Automated Charging

AGVs and AMRs may automatically connect to charging stations.

The charging system may communicate with the battery BMS and robot controller.

Battery information may include:

• SOC
• Ladezustand
• Temperatur
• Fehlerstatus
• Charging permission

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

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Custom Logistics Robot Battery Dimensions

Battery installation space is often defined by the robot’s mechanical structure.

A custom battery pack can be designed according to:

• Länge
• Breite
• Höhe
• Battery compartment
• Befestigungspunkte
• Anschlussposition
• Cable outlet
• Handle
• Enclosure structure

For an OEM battery project, useful mechanical information includes:

• Battery compartment drawing
• 2D mechanical drawing
• 3D model
• Connector drawing
• Mounting specifications

This information can be used to develop a battery enclosure that fits the available installation space.

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Battery Weight and Robot Design

Battery weight is another factor in logistics robot design.

The battery contributes to the total robot weight and may affect:

• Drive motor load
• Energieverbrauch
• Nutzlast
• Center of gravity
• Braking
• Mechanical structure

For this reason, battery capacity and battery weight should be considered together.

A battery with additional capacity also adds battery mass. The final configuration should therefore balance energy requirements with the robot’s mechanical and operational requirements.

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Battery Enclosure Design

The battery enclosure protects the cells, BMS, wiring, and other electrical components.

Possible enclosure materials include:

• ABS
• PC
• Aluminum
• Steel
• Engineering plastics

The enclosure can be designed to address:

• Mechanical protection
• Wärmeableitung
• Staubschutz
• Water protection
• Connector placement
• Kabelverlegung
• Mounting
• Wartungszugang

The appropriate enclosure structure depends on the robot’s working environment and mechanical requirements.

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Environmental Requirements

Logistics robots can operate in different environments, including:

• Lagerhallen
• Vertriebszentren
• Produktionsstätten
• Production lines
• Cold storage
• Loading areas

Potential environmental factors include:

• Temperatur
• Luftfeuchtigkeit
• Staub
• Water
• Vibration
• Mechanical impact

The battery design should define the required operating and charging temperature range.

For applications requiring protection against dust or water, an appropriate IP-rated enclosure can be considered.

The selected IP rating should be verified through applicable testing.

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Safety Design for Logistics Robot Lithium Batteries

Battery safety involves multiple components and design stages.

Zellauswahl

Battery cells should be evaluated according to:

• Kapazität
• Spannung
• Continuous current
• Peak current
• Innerer Widerstand
• Cycle requirements
• Betriebstemperatur
• Manufacturer specifications

BMS-Schutz

BMS parameters should be configured according to:

• Zellkonfiguration
• Batteriespannung
• Aktuell
• Temperatur
• Ladevorgaben
• Discharging requirements

Electrical Protection

A battery pack may include:

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

Thermal Design

Thermal considerations may include:

• Cell chemistry
• Aktuell
• Operating cycle
• Ambient temperature
• Enclosure
• Wärmeableitung

Mechanical Protection

The battery enclosure and mounting structure should be designed according to the vibration and mechanical conditions expected during robot operation.

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Logistics Robot Battery Testing

Battery testing should be defined according to the battery design, equipment requirements, and applicable standards.

Capacity Testing

Capacity testing can verify battery performance under defined charging and discharging conditions.

BMS Testing

BMS testing may evaluate:

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

Communication Testing

For smart battery systems, testing may include:

• CAN-Kommunikation
• RS485-Kommunikation
• UART-Kommunikation
• SOC data
• Fault reporting
• Ladezustand

Temperature Testing

Depending on the application, testing may include:

• High-temperature operation
• Betrieb bei niedrigen Temperaturen
• Charging at defined temperatures
• Überwachung der Temperatur

Mechanical Testing

Depending on the equipment requirements:

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

Testing requirements should be defined based on the actual battery design and intended application.

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Logistics Robot Battery Certifications and Compliance

Battery certification and compliance requirements depend on:

• Chemie der Batterie
• Batteriekonfiguration
• Product application
• Destination market
• Transportation method
• Applicable regulations

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

Depending on the product and target market, additional requirements may include:

• CE
• IEC-Normen
• UL-Normen
• RoHS
• EMC requirements
• 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 battery development stage rather than only after the battery has entered production.

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Custom Logistics Robot Battery Development Process

A structured development process helps connect the battery with the robot’s electrical and mechanical systems.

Step 1: Equipment Requirement Analysis

Collect:

• Robot model
• Nennspannung
• Motorleistung
• Average current
• Peak current
• Betriebszeit
• Ladevorgaben
• Abmessungen der Batterie
• Kommunikationsanforderungen

Step 2: Operating Profile

Evaluate:

• Tägliche Öffnungszeiten
• Operating cycles
• Nutzlast
• Reiseentfernung
• Driving speed
• Beschleunigung
• Lifting frequency
• Ladehäufigkeit

Step 3: Cell Selection

Evaluate:

• Cell chemistry
• Kapazität
• Spannung
• Current capability
• Innerer Widerstand
• Abmessungen
• Temperature specifications

Step 4: Battery Configuration

Determine:

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

Step 5: BMS Development

Define:

• Protection parameters
• Current rating
• Temperatursensoren
• SOC
• SOH
• CAN
• RS485
• UART

Step 6: Mechanical Design

Develop:

• Batteriegehäuse
• Befestigungskonstruktion
• Anschluss
• Cable
• Wiring harness
• Abmessungen der Batterie

Step 7: Prototype Production

The prototype can be evaluated for:

• Physical installation
• Electrical compatibility
• Aufladen
• Kommunikation
• Betriebszeit
• Temperatur
• Mechanical integration

Step 8: Testing

Testing can be performed according to:

• Spezifikationen der Batterie
• Equipment requirements
• Target market
• Applicable standards

Step 9: Validation and Production

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

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OEM and ODM Logistics Robot Battery Pack

OEM and ODM battery development allows the battery to be designed around the customer’s equipment.

Electrical Customization

• Spannung
• Kapazität
• Zellkonfiguration
• Entladungsstrom
• Chemie der Batterie

BMS Customization

• Protection parameters
• SOC
• SOH
• CAN
• RS485
• UART

Mechanical Customization

• Abmessungen der Batterie
• Enclosure
• Mounting
• Anschluss
• Cable
• Wiring harness

Charging Customization

• Ladespannung
• Ladestrom
• Kompatibilität mit Ladegeräten
• Charging communication

Product Customization

Depending on the project:

• Battery label
• Product identification
• Verpackung
• Technical documentation

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What Information Is Needed for a Custom Logistics Robot Battery?

For accurate battery engineering, the following information is useful:

Additional information can include:

• Equipment datasheet
• Original battery specifications
• Charger datasheet
• Motor datasheet
• Controller datasheet
• Battery compartment drawing
• Connector drawing
• Kommunikationsprotokoll
• 3D model

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How to Choose a Logistics Robot Battery Manufacturer

Selecting a battery manufacturer involves more than comparing battery prices.

For an OEM project, manufacturers can be evaluated based on engineering, production, testing, documentation, and compliance capabilities.

Battery Engineering Capability

The supplier should be able to evaluate:

• Zellauswahl
• Batteriekonfiguration
• BMS
• Current requirements
• Kommunikation
• Aufladen
• Mechanical integration

Manufacturing Capability

Relevant production processes may include:

• Cell grading
• Zellabgleich
• Schweißen
• PACK-Baugruppe
• BMS-Installation
• Aging
• Elektrische Prüfungen
• Endkontrolle

Testing Capability

Die Tests können Folgendes umfassen:

• Prüfung der Kapazität
• BMS testing
• Kommunikationstests
• Temperaturprüfung
• Vibrationsprüfung
• Waterproof testing when required

Dokumentation

For OEM battery projects, useful documents can include:

• Battery specification
• Cell datasheet
• BMS specification
• Test reports
• Certification documents
• Charging specifications
• Kommunikationsprotokoll

Technical claims should be supported by appropriate documentation.

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Engineering Considerations When Designing a Logistics Robot Battery

From a battery engineering perspective, capacity is only one part of the battery design.

A logistics robot battery should be evaluated through several parameters.

1. Energy

Battery energy can be estimated using:

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

2. Current

The battery should support the required continuous and peak current.

3. Operating Cycle

The battery requirement depends on how often the robot:

• Drives
• Stops
• Accelerates
• Turns
• Lifts
• Carries loads
• Returns to the charging station

4. Charging Strategy

The battery should be designed according to:

• Standard charging
• Opportunitätskosten
• Automated charging

5. Communication

When the robot controller requires battery information, the BMS may need:

• CAN
• RS485
• UART

6. Installation

The battery needs to fit the robot’s:

• Battery compartment
• Befestigungspunkte
• Anschlussposition
• Kabelverlegung
• Gewichtsbeschränkungen

7. Environment

The battery should be evaluated according to:

• Temperatur
• Luftfeuchtigkeit
• Staub
• Water
• Vibration

This engineering approach helps define the battery as part of the robot’s complete power system.

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Über Dongguan Yizhan Electronics Technology Co, Ltd.

Dongguan Yizhan Electronics Technology Co, Ltd. is a lithium battery PACK manufacturer providing customized battery solutions for industrial equipment and robotics applications.

The company’s battery development process can cover:

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

Battery applications include:

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

Depending on project requirements, battery packs can integrate:

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

The final battery configuration is determined according to the customer’s equipment specifications, operating conditions, charging requirements, communication system, mechanical structure, and target market.

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Why Customize a Battery for a Logistics Robot?

A standard battery may not match the electrical and mechanical requirements of a specific logistics robot.

Custom battery development can address several areas.

Elektrische Anforderungen

• Spannung
• Kapazität
• Aktuell
• Energie

Communication Requirements

• CAN
• RS485
• UART
• Other supported protocols

Mechanical Requirements

• Abmessungen
• Mounting
• Anschlussposition
• Cable length
• Enclosure

Charging Requirements

• Ladespannung
• Ladestrom
• Kompatibilität mit Ladegeräten
• Charging strategy

Environmental Requirements

• Betriebstemperatur
• Luftfeuchtigkeit
• Staub
• Water exposure
• Vibration

Compliance Requirements

• Transportation testing
• Market-specific regulations
• Applicable product standards

For OEM robotics manufacturers, these requirements can be defined during the robot development stage.

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Logistics Robot Battery Quality Control

Quality control should cover the battery from incoming cells to finished PACK.

A typical process may include:

Zellinspektion

Cells can be inspected for:

• Spannung
• Innerer Widerstand
• Kapazität
• Physical condition

Cell Matching

Cells can be grouped according to defined electrical parameters.

PACK Assembly

Battery assembly may include:

• Zellanordnung
• Sammelschienenanschluss
• Schweißen
• BMS-Installation
• Wiring
• Insulation
• Enclosure assembly

Funktionelle Prüfung

The finished battery can be tested for:

• Spannung
• Kapazität
• Aufladen
• Discharging
• BMS-Funktionen
• Kommunikation

Aging

Battery aging can be used to identify potential electrical or assembly issues before shipment.

Abschließende Inspektion

Final inspection can include:

• Erscheinungsbild
• Abmessungen
• Anschluss
• Spannung
• Kommunikation
• Schutzfunktionen
• Labeling

The specific inspection procedure depends on the battery design and production requirements.

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Logistics Robot Battery Selection Checklist

Before ordering a lithium battery for a logistics robot, confirm the following.

Elektrotechnik

☐ Nominal voltage
☐ Capacity
☐ Energy
☐ Continuous current
☐ Peak current
☐ Cell chemistry

BMS

☐ Overcharge protection
☐ Over-discharge protection
☐ Over-current protection
☐ Temperature protection
☐ SOC
☐ SOH
☐ Cell balancing

Kommunikation

☐ CAN
☐ RS485
☐ UART
☐ Communication protocol
☐ Data format

Aufladen

☐ Charging voltage
☐ Charging current
☐ Charger compatibility
☐ Charging method
☐ Automated charging requirements

Mechanical

☐ Battery dimensions
☐ Weight
☐ Mounting points
☐ Connector position
☐ Cable length
☐ Enclosure

Environment

☐ Operating temperature
☐ Charging temperature
☐ Humidity
☐ Dust
☐ Water exposure
☐ Vibration

Compliance

☐ UN 38.3
☐ Applicable IEC standards
☐ Applicable UL standards
☐ CE requirements
☐ RoHS
☐ EU Battery Regulation requirements where applicable

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FAQ

What type of battery is used in logistics robots?

Lithium-ion batteries, including LiFePO4 battery systems, can be used for logistics robots. The appropriate battery chemistry depends on the robot’s voltage, capacity, current, operating cycle, temperature, and installation requirements.

Can I customize a lithium battery for my logistics robot?

Yes. Voltage, capacity, dimensions, BMS, connectors, communication interfaces, enclosure, and charging specifications can be customized according to the robot’s requirements.

Can LiFePO4 batteries be used in logistics robots?

Yes. LiFePO4 is a lithium-ion chemistry that can be evaluated for logistics robot applications based on the robot’s electrical and operating requirements.

What voltage is used for logistics robot batteries?

The required voltage depends on the robot’s electrical system. Industrial battery systems may use configurations such as 24V, 36V, 48V, or 51.2V. The correct voltage should be determined from the equipment specifications.

Can a logistics robot battery communicate with the robot controller?

Yes. A smart BMS can support CAN, RS485, UART, or another communication interface when the BMS is configured to match the robot controller.

Can logistics robot batteries support automated charging?

Yes. A battery system can be designed for automated charging when the battery, BMS, charger, and robot controller support the intended charging architecture.

Can the battery dimensions be customized?

Yes. Battery dimensions, enclosure, mounting structure, connectors, cables, and wiring can be customized according to the robot’s installation space.

How do I calculate the required battery capacity?

Start with the robot’s voltage, average power consumption, operating time, peak current, charging schedule, and operating conditions.

The basic energy calculation is:

Wh = V × Ah

Actual battery capacity should be confirmed through the robot’s operating profile.

What certifications are required for logistics robot batteries?

Requirements depend on the battery, application, transportation method, and target market. UN 38.3 is relevant to lithium battery transportation, while additional regional or product-specific requirements may apply.

How long can a logistics robot battery operate?

Operating time depends on battery energy and the robot’s actual power consumption.

A basic estimate is:

Operating Time = Battery Energy ÷ Average Power Consumption

Actual runtime can vary according to payload, driving conditions, motor operation, auxiliary equipment, temperature, and battery operating parameters.

Can the battery support CAN communication and automated charging at the same time?

Yes. A battery can be designed with a smart BMS and CAN communication while supporting an automated charging system, provided the battery, charger, and robot controller are designed with compatible communication and charging requirements.

Schlussfolgerung

A Logistics Robot Battery is an integrated power system that needs to work with the robot’s electrical, mechanical, communication, and charging systems.

Battery development should consider:

Cell Chemistry + Voltage + Capacity + Current + BMS + Communication + Charging + Dimensions + Weight + Environment + Safety + Compliance

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

For logistics robots, AGVs, AMRs, and warehouse automation systems, a custom lithium battery pack can integrate:

• Batteriezellen
• BMS
• Protection components
• Temperatursensoren
• CAN-Kommunikation
• RS485-Kommunikation
• UART-Kommunikation
• Kundenspezifische Steckverbinder
• Custom wiring
• Custom enclosure

A structured OEM/ODM development process can follow:

Requirement Analysis → Cell Selection → Battery Configuration → BMS Design → PACK Design → Prototype → Testing → Validation → Production

For equipment manufacturers, defining battery requirements during the robot development stage can provide the engineering information needed for battery integration and validation.

Dongguan Yizhan Electronics Technology Co., Ltd. provides custom lithium battery PACK solutions for logistics robots, AGVs, AMRs, warehouse robots, and other industrial equipment according to OEM and ODM requirements.