Issue link: https://resources.mouser.com/i/1529320
22 Advancements in Industrial Automation 2,000 to 3,000 Charge Cycles Lithium-ion batteries last longer, typically 2,000 to 3,000 charge cycles, whereas lead-acid batteries tend to last around 1,000 to 1,500 cycles. The Electric Forklift and Lithium-Ion Advantage • Electric forklifts produce very few emissions. • With fuel and oil prices on the rise, electric forklifts can also provide operational savings. • Lithium-ion batteries in electric forklifts can be optimized for two- or multi-shift operations. • They do not need to be fully charged to function and can be charged whenever convenient. • Lead-acid batteries weigh about 9,000 pounds, while lithium-ion batteries weigh just 500 to 2,500 pounds. • The energy density of lithium-ion is between three and six times greater than lead-acid. • They pose no sulfation risk due to their internal chemistry. • They require no equalization charge or complex voltage setup to avoid damage during charging. • Lithium-ion batteries typically convert 95 percent of their energy into useful work, while lead-acid batteries only convert about 70 percent (and internal combustion engines even less). • Lithium-ion batteries can save operators thousands of dollars since they do not require the most expensive part of maintaining lead-acid batteries: watering. Using a Battery Management System Is Essential These new technologies, coupled with their opportunistic charging abilities, do require more sophisticated battery management systems, increased charging power, and more docking stations—plus compliance. Placing charging stations near break rooms, loading docks, or other convenient locations increases the likelihood of employee compliance. Thanks to these advancements in opportunistic charging, warehouse operators are now using electric forklifts more frequently in multi-shift operations to meet increased demand and leave unproductive downtime in the rearview mirror.