January 19, 2024 How Does BSLBATT Make Lithium Batteries Last Longer?

Learn how BSL improves lithium battery life with strong BMS, engineering and comprehensive product lifecycle infrastructure.

Forklift lithium batteries are becoming more and more popular. Some believe this may be due to changes in consumer preferences, such as warehouse managers who are conscious of reducing warehouse operating costs and a growing desire by forklift dealer companies to reduce fossil fuels. But what is the lifespan of a forklift lithium battery? does it worth?

With the development of technology, it is understandable that more and more people will have questions about forklift lithium batteries and their components. Below, BSL Battery – Industrial breaks down some details so you can start getting excited about these amazing lithium battery-equipped forklifts.

The growing importance of electric forklifts

In a world looking for consumer solutions to reduce fossil fuel emissions, electric forklifts are becoming increasingly important. In fact, total sales of electric forklifts will exceed 3 million units this year, according to Interact Analysis. This is an unprecedented achievement for the industry and has been sustained by the transformation of countless warehouse managers as well as forklift dealer companies to electric forklift-friendly infrastructure.

If you are a warehouse manager or one of the forklift dealer leasing companies, understanding forklift lithium batteries and battery management systems will quickly become part of your daily routine.

Learn about forklift lithium batteries

Lithium batteries are the first choice in various material handling industries due to their high energy density, long life, maintenance-free, extremely safe investment and fast charging. But let’s dig a little deeper.

Lithium Ion vs. Lead Acid: Pros and Cons

When it comes to energy storage, people often compare lithium-ion and lead-acid batteries. Lead-acid batteries have been around for a while, they are affordable and versatile. But what about lithium-ion batteries? They are the new kids and bring a lot of advantages.

Lithium-ion batteries charge faster, last longer, and have higher energy density than lead-acid batteries. They are also more environmentally friendly as they do not contain harmful lead and can be recycled. However, they have a higher upfront cost. But considering their benefits and longer lifespan, they offer an impressive return on investment.

Why lithium batteries are the choice of top industrial battery manufacturers

Top industrial battery manufacturers are increasingly leaning toward lithium batteries. There’s a good reason for this. Lithium batteries are more efficient, more reliable, and last longer allowing warehouse managers to recharge quickly. They also require less maintenance and are safer to use. In short, they offer excellent performance across the board.

Recommendations from the Top Forklift Lithium Battery Companies

So, how can we extend the service life of forklift lithium batteries? Let’s explore some expert tips.

1. Proper maintenance and operation

Forklift lithium batteries should be handled with care to maximize their service life. This includes avoiding physical stress, such as dropping or knocking the battery, and protecting the battery from harsh environments, such as extreme temperatures or moisture. Particularly in industries such as aviation ground support, refrigeration and manufacturing operations, where equipment may be used in harsh conditions, special care in properly handling and storing batteries can greatly extend their service life.

2. Best Charging Practices

Forklift lithium batteries have unique charging characteristics that can significantly extend their service life if used properly. For example, unlike other battery types, they do not need to be fully discharged before charging. This means they can be “opportunistically charged” during breaks or downtime without compromising battery life. This is particularly valuable for industries such as logistics and warehousing, where equipment often needs to be available around the clock.

3. Temperature management

Extreme temperatures can be harmful to forklift lithium batteries. They should be kept at room temperature whenever possible for best performance. However, in industries such as the refrigeration industry or certain manufacturing operations, where equipment may be exposed to extreme temperatures, choosing a lithium battery specifically designed to withstand such conditions can greatly improve its performance and longevity.

4. Monitor self-discharge rate

If you don’t plan to use your forklift lithium batteries for a while, be sure to store them properly to prevent damage. This means storing them in a cool, dry place and, ideally, partially charged. , the good news is that lithium-ion batteries have a low and stable self-discharge rate. The battery will first undergo an initial 5% discharge over 24 hours and then discharge at a rate of 1% to 2% per month. If the lithium-ion battery has a safety protection circuit, the monthly self-discharge rate will increase by up to 3%.

However, a forklift lithium-ion battery should never be completely drained to 0% or below 20%, roughly below its 2.50 volt/cell state. Using a battery management system (BMS) can help you monitor your battery’s state of charge as well as temperature and other factors. If the battery is low, you should charge it before placing it back in storage.

5. Charge/discharge correctly during use

Extreme overcharge and deep discharge cycles can put a lot of stress on lithium-ion batteries. When overcharged, dendritic lithium dendrites (whiskers) form on the negative electrode. These whiskers can cause serious problems because they are highly explosive to lithium-ion batteries.

To prevent whiskers, BSLBATT custom forklift lithium battery packs can be purchased with an equalizer to help balance the different module capacities in the battery pack. It improves the state of charge of the entire battery pack to prevent overcharging of cells with higher capacity than other cells in the pack. It will prevent the weakest batteries from overcharging and stop the lowest capacity batteries from discharging when they are close to empty.

To extend battery life, consider partial charging to 80% state of charge (SoC) rather than 100% charging. If the lithium battery is about to reach 100% charge, be sure to power off the device immediately after reaching that charge. Also, make sure to charge the battery in a cooler room. Room temperature is between 50°F and 95°F.

Depending on the lift truck equipment, operation, and available ventilation, the application should operate within a temperature range of 32° Fahrenheit to 95° Fahrenheit. Higher temperatures can cause batteries to discharge quickly. If your device is hot and the lithium-ion battery is discharging faster than normal, you may need to adjust the operation of your device.

6. The importance of a strong BMS

The battery management system (BMS) plays a vital role in the efficient operation and service life of industrial forklift lithium batteries. At its core, BMS controls power output and acts as a guardian of battery health, overseeing critical functions that directly impact performance and safety. One of its basic tasks is to regulate and optimize the charging and discharging process, balance the performance of each battery, and prevent overcharging or deep discharge, which can lead to capacity reduction or even safety hazards. In addition, BMS continuously monitors and maintains a suitable temperature range inside the battery pack to reduce the risk of thermal runaway and ensure optimal battery operation.

The importance of a reliable, state-of-the-art multi-function BMS becomes apparent when one considers the consequences of purchasing a lithium forklift battery pack equipped with an off-the-shelf BMS with limited functionality, which cheap battery brands exploit to cut corners. This generic BMS implementation lacks the sophistication required to address specific battery chemistries and device applications. As a result, batteries paired with a substandard BMS may experience reduced battery performance, reduced capacity, and shortened lifespan. Additionally, security concerns continue to escalate as these rudimentary BMSs can have difficulty detecting and managing potential issues, thereby increasing the likelihood of failure.

Essentially, the battery management system is the bulwark between seamless battery performance and potential setbacks. Its complex coordination of charging, discharging, communication and temperature control not only ensures efficient operation but also prevents premature wear and safety hazards, making it an integral part of battery technology.

7. Unleashing the Potential: Battery Chemistry and Engineering

The chemical composition of a lithium battery is the basic component of the battery and determines the upper limit of the battery’s cycle life. The two main contenders in the material handling space, lithium iron phosphate (LFP) and lithium nickel manganese cobalt oxide (NMC), as well as their traditional lead-acid counterparts, exemplify this chemistry-dependent variability in battery cycle life.

A conventional flooded lead-acid battery can last approximately 1,500 cycles before reaching the end-of-life stage, where it loses capacity and can no longer hold a charge. LFP and NMC batteries have a lifespan of 3000 to 7000 cycles or more. NMC cells have higher energy density and slightly higher voltage, while LFP cells excel in terms of longevity.

But battery chemistry alone does not determine cycle life. Engineering design plays an equally important role. For example, even though NMC cells exhibit higher values in terms of lifetime and energy density at the cell level under laboratory conditions, pack LFP cells outperform NMC cells at the pack level. Battery design can mitigate the effects of extreme temperatures, uneven cell aging, and stress-induced degradation, thereby increasing the overall life of the battery pack. In addition, a well-designed battery system with strong thermal management, efficient current distribution and optimal electrode configuration will extend the number of warranty cycles and service life.

8. Forklift battery pack design and engineering

Advanced industrial forklift lithium batteries are complex pieces of equipment, and like any piece of equipment of this class, they require expert support at every stage. The process begins with a pre-delivery inspection (PDI) of the battery, with expert guidance ensuring seamless integration with the charger and host vehicle. Proper setup ensures optimal performance and minimizes potential failures. BSL lithium batteries sit alongside SPE, Fronius and Delta-Q, reputable companies we admire and hope our partnership with SPE, Fronius and Delta-Q will take our relationships with OEMs to the next level. “

Trained technicians can usually resolve most common issues with battery performance within minutes, which is why battery manufacturers invest in training programs for their partners. A few hours spent on training can potentially save days of downtime and significantly increase equipment utilization. BSL has a complete set of forklift lithium battery training courseware and videos and can provide customers with two-week product training for free!

With deep visibility into real-time battery health and performance metrics, facility and warehouse managers can make calculated choices to improve efficiency and minimize operational disruptions. The foundation of this data-centric paradigm is accurate recording of battery specifications. By automatically recording and updating model codes and parameters for all battery components, technicians can ensure any issues with battery charging or performance are effectively diagnosed and resolved.

Bottom line

All in all, the life of lithium batteries is the result of the simultaneous action of multiple factors. A robust battery management system (BMS) is critical to ensuring optimal battery performance and avoiding premature failure. While battery chemistry limits cycle life, engineering design plays an important role in defining a battery’s guaranteed service life. Comprehensive product lifecycle infrastructure, including professional support, scheduled services, data collection and access, extends battery life and helps deliver sustainable and efficient power. By understanding and addressing these critical factors, we can unlock the full potential of lithium batteries and further improve energy storage efficiency.

So, what will be the lifespan of forklift lithium batteries in the future? This is a top concern for industry experts like BSL Battery – Industrial, which specializes in providing high-quality lithium forklift batteries to the material handling industry. If you would like to discuss the future of lithium forklift batteries with a family owned and operated manufacturer, call +86-752-2819469 today!

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