AGV lithium batteries solutions

What is the perfect AGV battery solution? Choose lithium iron phosphate or lithium ternary battery, the former has a long cycle life, high safety, has become the first choice for high-frequency AGVs; the latter has high energy density to ensure long range. Meanwhile, through intelligent BMS system real-time monitoring, adopting shallow charging and discharging strategy to prolong the battery life, and adopting branded battery cell, thus forming a perfect customized AGV batteries solution.

1.AGV lithium battery selection and technical requirements

1.1 Battery type selection

Lithium-ion battery (Li-ion): lithium iron phosphate (LiFePO₄) or lithium ternary (NCM/NCA) batteries are recommended, taking into account the energy density, cycle life and safety.

Lithium iron phosphate (LiFePO₄): high safety, long cycle life (2000-3000 cycles), suitable for high-frequency use of AGV.

Lithium ternary (NCM/NCA): high energy density (180-250Wh/kg), suitable for scenarios with high requirements for range.

1.2 Battery capacity

Capacity: Calculated according to AGV load, running time and power demand.

Formula: Capacity (Ah) = Average power (W) × Running time (h) / Battery voltage (V)

Example: AGV power 500W, need to work continuously for 8 hours, voltage 48V → capacity ≈ 83Ah

1.3 Battery Voltage

Voltage: commonly used 24V, 48V or 72V, need to match the AGV motor and controller voltage.

Select the battery that supports continuous discharge rate ≥ 1C (e.g. 1 hour discharge) to meet the high power demand of AGV acceleration and hill climbing.

It should be compatible with the structure of AGV body, and prioritize the selection of high energy density battery to reduce the weight of the whole vehicle.

1.4 Discharge rate (C-rate)

Considering the working environment and requirements of AGV, if AGV needs to operate with high power (such as loading heavy objects or moving at high speed), it is necessary to choose high discharge rate battery.

1.5 Battery size and weight

2. AGV lithium battery system design points

2.1 Battery structure

Modular design: standard cells (such as 18650 or square cells) are used to form a battery module, which is easy to maintain and replace.

Protection design: IP54 and above protection level, dustproof and waterproof, adapting to the complex environment of the factory.

2.2 Battery Management System (BMS)

Core functions:

Real-time monitoring of voltage/current/temperature;

Over-charging, over-discharging, short-circuit, over-temperature protection;

Cell equalization management to extend battery life;

SOC (state of charge) and SOH (state of health) estimation.

2.3 Communication interface: support CAN/RS485 communication, linkage with AGV main control system.

2.4 Charging mode:

Automatic charging pile docking: automatically docking charging pile when AGV is idle;

Wireless charging: suitable for contactless scenes, but less efficient (85-90%).

2.5 Charging strategy:

Shallow charging and discharging (SOC 20%-80%) to extend cycle life;

Support fast charging (1-2 hours full) to reduce downtime.

2.6 Charging Program.

3. Safety and Protection Design

3.1 Thermal management

Air-/liquid-cooled heat dissipation: High-power AGVs need to be equipped with an active heat dissipation system;

Temperature sensor: monitor the temperature of the electric core and trigger shutdown protection in case of abnormality.

3.2 Mechanical Protection

Battery shell adopts flame-retardant materials (e.g. V0 grade flame-retardant plastic);

Anti-vibration design: passes vibration test (e.g. IEC 62133 standard).

Multiple fuse and relay protection;

Insulation monitoring to prevent leakage.

3.3 Electrical Safety

4.Application Scenario Adaptation Program

4.1 Adaptation of different AGV types

Submerged AGV: small capacity (20-50Ah), lightweight battery (24V/48V);

Forklift AGV: large capacity (100-200Ah), high rate battery (72V).

4.2 Working environment adaptation

Low temperature environment: optional battery heating system (-20℃~60℃ working range);

High-temperature environment: enhanced heat dissipation design to avoid high-temperature degradation of the battery.

5. Maintenance and life management

5.1 Daily Maintenance

Regularly check the battery connector, heat dissipation system;

Clean the dust on the battery surface to avoid short circuit.

5.2 Life extension strategy

Avoid deep discharge (SOC not less than 20%);

Perform full discharge calibration every 3 months;

Storage conditions: 50% charge, temperature 15-25℃.

Replacement is recommended when battery capacity decays to 70%;

Cooperate with compliant recycling enterprises to execute environmental protection treatment.

5.3 End-of-life and recycling

6.Economy and Cost Analysis

6.1 Initial cost

Lithium iron phosphate battery: about 200-300 Euro/kWh;

Lithium ternary battery: about 230-330 Euro/kWh.

6.2 Long-term benefits

Compared to lead-acid batteries, Li-ion battery life is increased by more than 3 times, reducing the frequency of replacement;

Saving electricity cost (charging efficiency 95% vs lead-acid 80%).

7.Typical application cases

7.1 Automobile Manufacturing Workshop

AGV model: submerged handling robot;

Battery configuration: 48V/60Ah lithium iron phosphate battery, supporting 8 hours of range, 1.5 hours fast charging.

7.2 E-commerce warehousing and logistics

AGV model: forklift AGV;

Battery configuration: 72V/120Ah Li-ion ternary battery, supporting 10 hours of high-intensity operation.

8. Suppliers and services

8.1 Recommended battery cell brands

CATL, BYD , EVE .

8.2 Supporting services

Customized BMS development;

Remote monitoring platform (real-time battery status uploaded to the cloud).

With the above solution, the lithium battery system of AGV trucks can realize efficient, safe and long-life operation and meet the needs of intelligent manufacturing and logistics automation. Specific parameters need to be further optimized according to the actual working conditions.