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.
用途は以下の通り：
- 電動フォークリフト
- Electric walkie stackers
- パレットトラック
- 無人搬送車
- AMR
- Logistics robots
- Warehouse robots
- 検査ロボット
- Autonomous handling equipment
- 産業用ロボット
- 掃除ロボット
- Mobile platforms
Depending on the application, the battery may power:
- Traction motors
- Lifting systems
- Hydraulic systems
- Robotic actuators
- Controllers
- センサー
- Communication systems
- Displays
- 安全システム
- 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:
- 必要電圧
- バッテリー容量
- 連続電流
- ピーク電流
- 稼働時間
- 充電に関する要件
- バッテリー寸法
- 通信プロトコル
- 環境条件
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
電動フォークリフト
Electric forklifts require battery systems for traction and lifting functions.
A custom lithium battery can be designed according to:
- Forklift voltage
- モーター出力
- 営業時間
- 負荷要件
- Charging schedule
- 電池ケース
- BMSの要件
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:
- 電圧
- 定員
- Motor current
- Lifting current
- バッテリー寸法
- コネクタ
- 充電器
- 通信インターフェース
Smart BMS functions can also be integrated when battery information needs to be exchanged with the equipment controller.
パレットトラック
Electric pallet trucks use batteries for traction and lifting functions.
Battery design can consider:
- Compact installation space
- Operating cycle
- ピーク電流
- 充電頻度
- バッテリー重量
- コネクタの設定
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
- チャンスチャージ
- Long operating schedules
- BMS通信
- 車両管理システム
A custom AGV battery pack can include:
- LiFePO4セル
- スマートBMS
- CAN通信
- RS485通信
- Custom connectors
- バッテリー監視
- 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
- Cameras
- LiDAR
- Industrial computers
- Wireless communication
- Safety sensors
- 駆動モーター
- 制御システム
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:
- 営業時間
- 平均消費電力
- ピーク出力
- Charging schedule
- Payload
- 移動距離
- 電池ケース
- 通信要件
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:
- 駆動モーター
- 制御システム
- センサー
- 通信モジュール
- Industrial computers
- Lifting mechanisms
Battery customization can include:
- 電圧
- 定員
- セルの構成
- ビーエムエス
- CAN
- RS485
- UART
- コネクタ
- 住宅
- 取付構造
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:
- 駆動モーター
- Cameras
- LiDAR
- センサー
- 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:
- 電圧
- 現在
- 温度
- SOC
- 障害状況
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:
- モーター出力
- Robot payload
- Operating cycle
- Movement pattern
- Control system
- Auxiliary equipment
- 職場環境
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:
- 熱安定性
- 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.
例えば、こうだ：
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
バッテリーのエネルギーは、以下の式を用いて推定できます：
エネルギー（Wh）＝電圧（V）×容量（Ah）
例えば、こうだ：
48V × 100Ah = 4,800Wh
これはおよそ 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:
- Motor operation
- Payload
- 移動距離
- 加速
- リフティング
- Auxiliary loads
- 温度
- Battery operating window
- システムの効率
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:
- Startup
- 加速
- Braking
- リフティング
- 旋回
- Ramp operation
- Motor loading
- Robotic movement
The battery pack should therefore be evaluated according to:
連続電流
そして
ピーク電流
The following components should also be matched to the electrical load:
- バッテリーセル
- ビーエムエス
- ヒューズ
- バスバー
- ケーブル
- コネクタ
- 保護部品
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:
- 個々の細胞の電位
- パック電圧
- 充電電流
- 放電電流
- 細胞温度
- バッテリー温度
- SOC
- SOH
保護機能には、次のようなものがあります：
- 過充電保護
- 過放電保護
- 過電流保護
- 短絡保護
- 過熱保護
- 低温保護機能
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:
- バッテリー電圧
- 現在
- SOC
- 温度
- 充電状況
- 障害情報
- Battery status
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.
重要な充電パラメータには、以下のものがあります：
- 電池の化学組成
- 公称電圧
- 充電電圧
- 充電電流
- 充電プロファイル
- コネクタ
- BMS通信
- 充電可能温度範囲
For automated equipment, charging can be integrated into the operating process.
Charging methods may include:
- Standard charging
- チャンスチャージ
- スケジュール充電
- Automated charging
The charging method should be compatible with the battery, BMS, charger, and equipment control system.
機会充電
Opportunity charging allows equipment to receive charging during available idle periods.
It may be considered for:
- 無人搬送車
- AMR
- 電動パレットトラック
- ウォークイースタッカー
- Warehouse robots
- Automated material handling systems
Charging may take place during:
- Breaks
- シフト交代
- 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
- 充電状況
- バッテリー温度
- 障害状況
- 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:
- 長さ
- 幅
- 高さ
- Mounting holes
- Battery tray
- コネクタの位置
- ケーブル出口
- ハンドル
- 添付資料
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
- アルミニウム
- 鋼
- Other engineering materials
The enclosure design can consider:
- 機械的保護
- 放熱
- 水資源保護
- 防塵対策
- コネクタの配置
- ケーブルの配線
- Mounting
- サービスへのアクセス
The final material and enclosure structure should be selected according to the application.
環境要件
Material handling equipment may operate in:
- 倉庫
- 工場
- 冷蔵倉庫
- 物流センター
- Outdoor logistics areas
- Industrial facilities
Environmental conditions may include:
- ダスト
- 湿度
- 気温の変化
- 水への曝露
- 振動
- 機械的衝撃
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:
細胞の選択
Cells should be evaluated according to:
- 定員
- 電圧
- 連続電流
- ピーク電流
- サイクル要件
- 温度範囲
- メーカー仕様
ビーエムエス
The BMS should be configured according to:
- セルの構成
- 電圧
- 現在
- 温度
- Protection limits
- 通信要件
電気的保護
The battery may include:
- ヒューズ
- Protection circuit
- バスバー
- 断熱
- Rated connectors
- Appropriate cables
熱管理
Thermal design should consider:
- セルタイプ
- 現在
- Operating cycle
- 周囲温度
- 添付資料
- 放熱
機械的保護
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
収集：
- Equipment model
- 電圧
- モーター出力
- 現在
- 営業時間
- 電池ケース
- 充電器
- 通信プロトコル
Step 2: Operating Profile
評価：
- Daily operating time
- Operating cycles
- Payload
- 移動距離
- リフトの頻度
- 充電の機会
- 周囲温度
Step 3: Battery Chemistry
評価：
- LiFePO4
- エヌエムシー
- Other lithium-ion chemistries
The chemistry should be selected according to the equipment requirements.
Step 4: Cell Selection
評価：
- セル容量
- 電圧
- 現在
- 内部抵抗
- Cycle characteristics
- Temperature specifications
- 外形寸法
Step 5: Battery Configuration
次のことを決定する：
- 直列接続
- 並列接続
- 公称電圧
- 定員
- エネルギー
- 現在の能力
Step 6: BMS Design
Define:
- 保護パラメータ
- 定格電流
- 温度センサー
- SOC
- SOH
- CAN
- RS485
- UART
Step 7: Mechanical Design
開発：
- 添付資料
- 取付構造
- コネクタ
- ケーブル
- ワイヤーハーネス
- バッテリー寸法
Step 8: Prototype
Build a prototype for:
- Installation verification
- 電気試験
- Charging verification
- 通信テスト
- 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.
電気試験
- キャパシティ・テスト
- Charge testing
- Discharge testing
- 電圧試験
- Current testing
- BMS保護機能の試験
BMS試験
- 過充電保護
- 過放電保護
- 過電流保護
- 短絡保護
- 温度保護
- セルバランシング
通信テスト
- CAN
- RS485
- UART
- SOC communication
- Fault reporting
- Data transmission
環境試験
Depending on the application:
- 高温試験
- 低温試験
- 温度サイクル試験
- Humidity testing
- Water protection testing
- Dust protection testing
機械的試験
- 振動試験
- Impact testing
- コネクタの試験
- Mounting testing
- Enclosure inspection
認証とコンプライアンス
Lithium battery requirements depend on the battery design, application, transportation method, and target market.
For lithium batteries transported internationally, 国連 38.3 is an important transportation testing requirement.
Depending on the product and destination market, applicable requirements may include:
- CE
- IEC規格
- UL規格
- RoHS
- EMC requirements
- Regional battery regulations
For products placed on the European market, applicable requirements under EU電池規則（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:
| パラメータ | Information |
|---|---|
| 機器の種類 | Forklift / AGV / AMR / Robot |
| 電池の化学組成 | LiFePO4 / Li-ion |
| 公称電圧 | V |
| 定員 | あ |
| 連続電流 | A |
| ピーク電流 | A |
| 稼働時間 | 営業時間 |
| 充電時間 | 営業時間 |
| 充電器 | Model / Specifications |
| コミュニケーション | CAN / RS485 / UART |
| バッテリー寸法 | 長さ × 幅 × 高さ |
| コネクタ | Model / Custom |
| 動作温度 | °C |
| IP requirement | 用途による |
| ターゲット市場 | EU / US / Other |
| 数量 | Prototype / Production |
Additional information can include:
- Equipment datasheet
- Original battery label
- Charger datasheet
- Motor specifications
- コントローラの仕様
- Battery compartment drawing
- Connector drawing
- 通信プロトコル
- 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.
技術力
The manufacturer should be able to evaluate:
- 電池の化学組成
- セルの構成
- ビーエムエス
- 現在の要件
- コミュニケーション
- 充電器の互換性
- 機械構造
- Thermal requirements
製造能力
Relevant production capabilities may include:
- 細胞選別
- 溶接
- PACK assembly
- BMS設置
- バッテリーの経年劣化
- 電気試験
- 機能テスト
- 最終検査
Testing Capability
The manufacturer should have testing processes appropriate to the battery application.
These may include:
- キャパシティ・テスト
- エージング試験
- BMS試験
- 温度試験
- 振動試験
- 防水試験
- 通信テスト
認証サポート
The manufacturer should be able to explain:
- Existing certification
- Applicable standards
- Testing requirements
- Documentation
- 輸送に関する要件
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:
電気
- 電圧
- 定員
- 現在
- セルの構成
ビーエムエス
- 保護パラメータ
- SOC
- SOH
- CAN
- RS485
- UART
機械
- 寸法
- 添付資料
- Mounting
- コネクタ
- ケーブル
- ワイヤーハーネス
充電
- 充電電圧
- 充電電流
- 充電コネクタ
- 充電通信
Branding
Depending on the project, OEM customization may include:
- Battery label
- Product identification
- パッケージ
- User documentation
About Our Lithium Battery Manufacturing Experience
東莞伊湛電子科技有限公司 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:
- 電動フォークリフト
- ウォークイースタッカー
- パレットトラック
- 無人搬送車
- AMR
- Logistics robots
- 検査ロボット
- 産業用ロボット
- 倉庫用機器
- Other mobile industrial equipment
Depending on project requirements, battery packs can be configured with:
- LiFePO4セル
- リチウムイオン電池
- スマートBMS
- CAN通信
- RS485通信
- UART通信
- Custom connectors
- 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:
- モーター
- コントローラー
- 充電器
- ビーエムエス
- センサー
- ディスプレイ
- 通信システム
- Safety system
- 機械構造
For this reason, battery development should begin with equipment requirements.
Early technical evaluation can help define:
- 電圧
- 定員
- 現在
- バッテリー寸法
- ビーエムエス
- コミュニケーション
- 充電器
- コネクタ
- Mounting
- 環境要件
This process provides a technical foundation for prototype development and production.
よくあるご質問
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.
結論
Lithium batteries can be configured for a wide range of material handling equipment and robotics applications.
これらには以下が含まれる：
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.
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