How has fast charging enhanced the use of electric-powered forklift trucks?
The fast charging concept was first applied to industrial forklift truck batteries in the 1990s when it was realized that on-road consumer electric vehicles had little to no market potential. Although many users and battery OEMs alike were quite skeptical, extended field trials have demonstrated the viability of fast charging technology and the durability of industrial batteries.
Benefits of Using a Single Battery with Fast Charging Systems
With fast charging systems for forklifts, and due to the higher charging rate and more frequent charging throughout the day, a single battery per truck is needed.
This eliminates the need for additional batteries. It also improves truck driver productivity, as it removes the time wasted in changing batteries during two- and three-shift applications.
In addition, since the system uses a single battery, it achieves a 100% battery utilization factor (full utilization of the asset).
Additional savings may come from the improved efficiency of fast chargers compared to conventional chargers.
There’s also an improvement in worker safety, as employees no longer need to move batteries in and out of the truck on a regular basis.
What types of plants is fast charging best suited for?
Fast charging of industrial batteries is a main stream charging technology due to the operational savings, increased productivity and safety that this technology offers. Users have realized the benefits of fast charging systems for forklifts. They continue to realize the benefits at manufacturing plants and distribution centers throughout the United States.
What are the best applications for fast charging? What are the limitations of fast charging?
If you operate (plan to operate) battery powered trucks at least 1.5+ shifts per day and do (or anticipate doing) at least one battery change out per day, you may be a candidate for fast charging. The next step is to understand the operational profile of the trucks and batteries. This will help determine if fast charging is actually feasible. A power study can establish this by monitoring the battery/truck operation throughout the week. For the collected data, one can establish whether there are adequate opportunities for fast charging throughout the shift or day. There should also be a weekly opportunity to perform a finish/equalize cycle.
Opportunity Charging
- Charging rates of 25A/100 Ahrs
- 4-6 hour charge intervals (1.5+ shift applications)
- 100% daily recharge
Fast Charging
- Charging rates of 40+A/100Ahrs
- 2-4 hour charge intervals (1.5-2+ shift applications)
- Charge during breaks, lunches, and at the end of shifts
- Common to recharge from 30-80% state of charge (SOC) in 1-2 hour intervals
- 80-85% daily recharge; 100% recharge once per week
- Requires battery modifications and accessories
- Allows operations to run on 1 battery per truck
- Eliminates battery changing
- Battery utilization: 100%