Lithium Batteries for Electric Forklifts and Material Handling Equipment

Lithium batteries are used in electric forklifts, pallet trucks, stackers, automated guided vehicles (AGVs), and other material handling equipment. These machines rely on battery systems to power traction motors, hydraulic systems, control units, and electrical components.

For equipment manufacturers, selecting a lithium battery involves electrical specifications, mechanical integration, charging requirements, and operating conditions.

Lithium batteries for electric forklifts and material handling equipment must be evaluated according to the vehicle’s voltage, capacity, discharge current, battery compartment, and operating cycle.

Battery Management System (BMS) functions, charging interfaces, communication requirements, and applicable safety standards are also part of the development process.

This article explains the technical considerations involved in lithium battery selection and custom battery pack development for electric forklifts and industrial material handling applications.

1. Lithium Battery Applications in Material Handling Equipment

Material handling equipment is used in warehouses, manufacturing facilities, distribution centers, and logistics operations.

Different equipment types have different electrical and mechanical requirements.

Les applications les plus courantes sont les suivantes

Chariots élévateurs électriques

Electric forklifts use battery systems to supply power for vehicle movement, lifting, and other electrical functions.

Battery requirements depend on the forklift model, rated load, motor controller, hydraulic system, and operating conditions.

Electric Pallet Trucks

Electric pallet trucks are used to transport goods over warehouse floors.

Battery specifications depend on the equipment’s motor power, operating cycle, charging method, and installation space.

Electric Stackers

Electric stackers use battery power for traction and lifting functions.

Battery design should consider the current required during movement and lifting operations.

Chariots à mât rétractable

Reach trucks are used in warehouse storage and material handling applications.

Battery selection should follow the vehicle manufacturer’s electrical and mechanical specifications.

AGV et AMR

Automated Guided Vehicles (AGVs) and Autonomous Mobile Robots (AMRs) are used in automated material handling systems.

Their battery packs may require customized dimensions, BMS functions, and communication interfaces.

Each equipment application requires evaluation of the battery voltage, current, capacity, enclosure structure, and charging requirements.

2. Selecting Battery Voltage for Electric Forklifts

Battery voltage is a basic parameter in industrial battery design.

The required voltage depends on the vehicle’s motor controller, drive system, electrical components, and charging system.

Voltage classes encountered in material handling equipment include:

• 24V
• 36V
• 48V
• 80V

The actual battery voltage depends on the selected chemistry and series cell configuration.

LiFePO4 Battery Configurations

LiFePO4 battery cells have a typical nominal voltage of 3.2V per cell.

Examples of series configurations include:

LiFePO4 Configuration	Tension nominale	Equipment Voltage Class
8S	25.6V	24V class
12S	38.4V	Application-dependent
15S	48.0V	48V class
16S	51.2V	48V class, subject to compatibility
25S	80.0V	80V class

These configurations are calculation examples. They do not represent specific products of Dongguan Yizhan Electronics Technology Co., Ltd.

Equipment voltage classes do not establish the permitted battery operating voltage range.

Before selecting a battery configuration, the forklift manufacturer should confirm:

• Nominal system voltage
• Motor controller operating voltage range
• Maximum allowable battery voltage
• Minimum operating voltage
• Charging voltage requirements
• Compatibility with the existing electrical system

A battery pack should not be selected based only on a nominal voltage label.

3. Battery Capacity and Operating Time

Battery capacity determines the amount of electrical charge available under specified operating conditions.

Capacity is expressed in ampere-hours (Ah), while battery energy is expressed in watt-hours (Wh) or kilowatt-hours (kWh).

Battery Energy Calculation

Nominal battery energy can be calculated using:

Energy (Wh) = Nominal Voltage (V) × Capacity (Ah)

For example, a theoretical LiFePO4 battery pack with:

• Tension nominale : 51,2 V
• Capacity: 200Ah

Has a nominal energy of:

51.2V × 200Ah = 10,240Wh = 10.24kWh

This example is for calculation purposes and does not represent an existing product of Dongguan Yizhan Electronics Technology Co., Ltd.

Factors Affecting Battery Capacity Selection

Required battery capacity depends on:

• Consommation électrique des équipements
• Heures de fonctionnement
• Load weight
• Travel distance
• Lifting frequency
• Acceleration and braking cycles
• Charging intervals
• Température ambiante
• Equipment standby consumption

For forklift projects, customers should provide the vehicle’s electrical specifications and operating duty cycle.

Battery capacity should be evaluated according to the expected energy consumption and required operating time.

4. Continuous and Peak Discharge Current Requirements

Electric forklifts and industrial handling equipment may draw different currents during normal travel, motor startup, and lifting operations.

Continuous discharge current and peak discharge current should be defined separately.

Courant de décharge continu

Continuous discharge current refers to the current required during sustained operation.

This parameter affects:

• Sélection des cellules de batterie
• BMS current rating
• Busbar design
• Power cable selection
• Connector specifications
• Gestion thermique

Courant de décharge de pointe

Peak discharge current refers to a short-duration current demand.

Current pulses may occur during:

• Vehicle acceleration
• Motor startup
• Hydraulic lifting
• Movement under load
• Changes in operating conditions

For example, a proposed battery specification may require:

Paramètres	Illustrative Requirement
Tension nominale	51.2V
Capacité	200Ah
Courant de décharge continu	100A
Courant de décharge de pointe	200A
Peak Current Duration	5 seconds

These values are illustrative engineering requirements, not verified production battery specifications.

The peak current duration and repetition frequency should be confirmed during technical evaluation.

The selected battery cells, BMS, electrical connections, and connectors must be evaluated according to the complete current profile.

5. LiFePO4 Battery Cell Selection for Forklift Applications

Lithium Iron Phosphate (LiFePO4) is a battery chemistry used in industrial traction and material handling applications.

Cell selection depends on the required electrical specifications, battery dimensions, operating temperature, and equipment requirements.

Prismatic LiFePO4 Cells

Prismatic cells are used in industrial battery modules and energy storage systems.

Their rectangular structure allows engineers to design battery arrangements according to the available enclosure dimensions.

Cell selection should consider:

• Capacité nominale
• Courant de décharge continu
• Pulse current capability
• Résistance interne
• Cycle life specifications
• Température de fonctionnement
• Cell dimensions
• Terminal structure
• Manufacturer documentation

Series and Parallel Configuration

Battery cells are connected in series and parallel to obtain the required voltage and capacity.

Series connections determine the pack voltage.

Parallel connections determine the combined capacity and contribute to the pack’s current capability.

The configuration must also account for the available installation space, electrical connections, insulation, and thermal conditions.

Cell Manufacturer Requirements

If a forklift project specifies a particular cell manufacturer or model, the requirement should be included in the technical documentation.

The final cell configuration should be evaluated according to the manufacturer specifications and the equipment’s electrical load.

6. Battery Management System Requirements

The Battery Management System (BMS) monitors battery conditions and provides protection functions according to its hardware and firmware configuration.

For forklift and material handling battery packs, BMS requirements should be defined during the design stage.

Electrical Protection Functions

Depending on the design, BMS functions may include:

• Protection contre les surcharges
• Protection contre la surcharge
• Protection contre les surintensités
• Protection contre les courts-circuits
• Protection de la température
• Surveillance du potentiel cellulaire
• Équilibre cellulaire

Current Monitoring

The BMS may monitor charging and discharging current according to its measurement system.

The continuous current rating and peak current requirements should be evaluated alongside the selected electrical protection components.

Contrôle de la température

Temperature sensors may be installed at defined locations within the battery pack.

Monitoring positions can include selected cells, electrical connections, and BMS components.

The number and location of sensors depend on the battery configuration and thermal design.

SOC and SOH Reporting

Depending on the BMS configuration, battery information may include:

• État de charge (SOC)
• État de santé (SOH)
• Tension de la batterie
• Battery current
• Température de la batterie
• État des défauts

The availability of these functions should be confirmed according to the selected BMS hardware and firmware.

7. CAN Communication for Electric Forklift Batteries

Some industrial vehicles and material handling systems require battery information to be transmitted to the equipment controller.

CAN communication may be used for this purpose.

A CAN-enabled BMS can transmit defined battery information according to an agreed communication protocol.

The transmitted information may include:

• Tension de la batterie
• Battery current
• SOC
• Température de la batterie
• Statut de protection
• Informations sur les pannes

CAN Protocol Requirements

For battery projects requiring CAN communication, customers should provide:

• CAN bit rate
• CAN identifiers
• Message format
• Data definitions
• Transmission intervals
• Connector pin assignments
• Required status information

CAN Monitoring and Control

CAN communication does not automatically provide control over battery charging or discharging.

In a monitoring-only configuration, CAN transmits battery information to the equipment controller.

Charging and discharging functions depend on the BMS electrical design and connected equipment.

If the project requires CAN-based control functions, these requirements must be defined and evaluated separately.

8. Charging Systems for Forklift Lithium Batteries

Battery charging is part of the equipment’s operating system.

The required charger specifications depend on the selected battery cells, battery configuration, BMS, and vehicle design.

Tension de charge

The charger output voltage must be compatible with the battery’s charging voltage requirements.

Courant de charge

Charging current should be selected according to the cell manufacturer specifications and battery pack design.

Charging Connectors

Charging connector selection should consider:

• Rated voltage
• Rated current
• Connector structure
• Caractéristiques techniques des câbles
• Position de montage
• Mechanical protection
• Conditions environnementales

Charger Communication

Some charging systems use communication between the battery, charger, and equipment controller.

The communication protocol and charging current control responsibilities should be defined during system integration.

Charging Operation

Equipment manufacturers should confirm whether the forklift uses:

• Recharge manuelle
• Battery removal for charging
• Onboard charging
• Dedicated charging stations
• Scheduled charging during operating breaks

The charging arrangement affects the electrical interface, mechanical structure, and project requirements.

9. Mechanical Design and Battery Compartment Requirements

The battery pack must fit within the equipment’s designated installation compartment.

For custom forklift lithium battery packs, mechanical requirements may include:

• Autonomie de la batterie
• Largeur de la batterie
• Hauteur de la batterie
• Poids de la batterie
• Mounting positions
• Cable outlet positions
• Connector locations
• Enclosure material
• Maintenance access

Battery Enclosure

Industrial battery enclosures may use metal structures designed according to the mechanical requirements.

The enclosure should account for:

• Cell mounting
• Electrical insulation
• Mechanical support
• Vibration conditions
• Connector protection
• Dissipation thermique
• Installation and removal procedures

Battery Weight and Forklift Stability

Battery weight requires specific attention in forklift applications.

For certain electric forklifts, battery mass contributes to the vehicle’s stability and counterweight arrangement.

A lithium battery pack should not be treated as a direct replacement for an existing battery based only on voltage, capacity, and compartment dimensions.

When replacing or modifying a battery system, the equipment manufacturer should confirm:

• Permitted battery weight range
• Battery compartment requirements
• Vehicle stability requirements
• Counterweight arrangement
• Mounting and retention requirements
• Approval requirements for changes to the vehicle

Battery weight and vehicle modifications must follow the equipment manufacturer’s instructions and applicable safety requirements.

10. Thermal Management and Operating Conditions

Forklift batteries generate heat during charging and discharging.

Thermal behavior depends on the battery cell model, current, electrical resistance, operating temperature, and enclosure design.

Thermal considerations include:

• Courant de décharge continu
• Peak current duration
• Courant de charge
• Disposition des cellules
• BMS temperature
• Enclosure material
• Température ambiante
• Dissipation thermique

Température de fonctionnement

Customers should provide the specified operating temperature range.

For example, forklifts operating in refrigerated warehouses may require evaluation of battery discharge performance and charging temperature restrictions.

Charging and discharging temperature limits should be considered separately.

Dust and Water Protection

Material handling equipment may operate in warehouses or industrial environments involving dust and moisture.

If an ingress protection rating is required, the complete battery enclosure should be evaluated according to the specified IP classification.

The required rating depends on the installation environment and equipment requirements.

11. Battery Safety Standards and Testing Requirements

Battery testing and certification requirements depend on the application, destination market, and product classification.

The following standards may be relevant during project evaluation.

Standard	Application or Purpose
IEC 62619	Safety requirements for secondary lithium cells and batteries used in industrial applications
UN38.3	Lithium battery transportation testing
IEC 60529	Degrees of protection provided by enclosures
UL 2580	Safety evaluation of batteries for electric vehicles, where applicable

The applicable standards should be confirmed according to the battery product and target market.

Electrical Validation

Electrical testing may include:

• Voltage inspection
• Vérification de la capacité
• Essais de charge et de décharge
• Continuous current evaluation
• Peak current testing
• BMS protection verification

Mechanical Validation

Depending on the application, mechanical validation may include:

• Dimensional inspection
• Enclosure inspection
• Mounting verification
• Essais de vibration
• Inspection des connecteurs

Thermal Validation

Thermal evaluation may include:

• Temperature rise testing
• Operating temperature evaluation
• Temperature sensor verification
• BMS temperature protection testing

The testing scope and acceptance criteria should follow the approved project requirements.

Engineering validation does not automatically establish formal product certification.

12. Information Required for a Custom Forklift Battery Quotation

When requesting a custom lithium battery pack for a forklift or material handling application, customers should provide the following information.

Objet	Required Information
Equipment Type	Forklift, pallet truck, stacker, reach truck, AGV or other equipment
Equipment Manufacturer	Brand and model
Tension nominale	Tension requise
Capacité de la batterie	Ah or Wh
Courant de décharge continu	A
Courant de décharge de pointe	A and duration
Composition chimique des batteries	LiFePO4 or specified chemistry
Dimensions de la batterie	Longueur × Largeur × Hauteur
Poids de la batterie	Required or permitted weight range
BMS Requirements	Protection and monitoring functions
Communication	CAN, UART, RS485 or other interface
Charging	Voltage, current and charger specifications
Connecteurs	Charging, discharging and communication interfaces
Température de fonctionnement	Charging and discharging temperature ranges
Environmental Requirements	Dust, moisture and vibration
Certification	Applicable standards and target market
Prototype Quantity	Required sample quantity
Production Quantity	Initial order and estimated annual demand
Delivery Destination	Country and address

For forklift applications, customers should also provide the vehicle manufacturer’s battery installation specifications and applicable approval requirements.

These details are used to evaluate the battery configuration, mechanical design, electrical components, and project scope.

13. Custom Industrial Lithium Battery Packs at Dongguan Yizhan Electronics Technology Co., Ltd.

Dongguan Yizhan Electronics Technology Co. Ltd. provides OEM and ODM custom lithium battery pack development and manufacturing services for electric mobility, robotics, industrial equipment, and energy storage applications.

Our customization scope includes:

• LiFePO4 and ternary lithium-ion battery configurations
• Customized battery voltage and capacity
• Sélection des cellules de batterie
• BMS configuration according to project requirements
• CAN, UART, and RS485 communication options
• NTC temperature monitoring
• Customized connectors and wiring
• Plastic and metal battery enclosures
• Battery pack assembly
• Technical documentation and project testing coordination

For material handling battery projects, electrical specifications, installation dimensions, operating current, communication interfaces, and environmental requirements are considered during technical evaluation.

Forklift-specific battery requirements, including battery weight, vehicle compatibility, and relevant safety requirements, must be confirmed according to the equipment manufacturer’s specifications.

The battery configuration and manufacturing scope are determined according to the confirmed project requirements.

Conclusion

Lithium batteries are used in electric forklifts and material handling equipment with defined electrical, mechanical, and operating requirements.

Battery selection involves voltage, capacity, continuous and peak discharge current, BMS protection, charging systems, connectors, and enclosure design.

For forklift applications, battery weight and vehicle stability must also be considered during battery selection or replacement projects.

OEM and ODM customers should provide equipment specifications, battery compartment dimensions, electrical requirements, and production quantities during the quotation stage.

Looking for a custom lithium battery pack for material handling equipment?

Contact Dongguan Yizhan Electronics Technology Co. Ltd. with your equipment model, battery voltage, capacity, discharge current, installation dimensions, BMS requirements, and estimated order quantity.

Our team can review the project specifications and discuss a battery configuration based on the equipment requirements.