Opportunity charging is a practice applicable to both Lead Acid and Lithium-ion (Li-ion) batteries for motive power systems and especially useful for Material Handling (MH) Equipment. Fast charging is a key differentiator for Lithium- ion batteries. Because the chemistry allows fast charging without damaging cycle life, Green Cubes' Lithium SAFEFlex Li-ion batteries can be charged opportunistically during breaks and don’t require battery swaps.
Our state-of-the-art Lithium SAFEFlex chargers employ high-frequency technology for the most compact, efficient for the widest voltage range available on the market today. Multiple outputs and automatic voltage detection via CAN communication enable simultaneous charging of multiple trucks with a single utility connection. The modular design allows an entire fleet, from pallet jacks to forklifts, to be serviced, opportunity charging around the clock.
Charging Li-ion Batteries
Li-ion batteries are preferably charged using a Constant Current / Constant Voltage (CC/CV) charge regime, but most MH equipment batteries are designed to accept both CC/CV and FLA charge regimens. Regardless of the state-of-charge of the battery when connected to the charger, the battery will efficiently accept the power and increase its state-of-charge. Whether the battery has been connected to the charger for 15 minutes or two hours, that battery can be immediately discharged and used by the MH equipment as there is no need to cool or rest a Li-ion battery after charging.
The Li-ion cell chemistry has numerous chemical variants. Lithium Iron Phosphate (LFP) chemistry is the predominant chemistry used to power MH equipment: LFP features:
- exceptionally long cycle life (2000 - 4000 cycles to reach 80% of the original capacity)
- high power capabilities for both charge and discharge
- lower energy/density than other Li-ion variants.
The long cycle life means an LFP battery can be installed and remain in the equipment for 8-10 years. More importantly, since LFP chemistry can accommodate high power delivered to and from the battery, a depleted LFP battery can accept a full charge in a little over one hour (i.e. 1 C rate) and it can be delivered throughout the shift when the operator has a break or lunch. Li-ion is the optimal chemistry for opportunity charging.
Best Practices for Opportunity Charging
- Do a power study where the battery activity is monitored. Based on the data, one can determine whether there are adequate opportunities for charging throughout the shift. If there is no down-time for the equipment throughout the shift, then the batteries will need to be charged for an hour before the shift.
- Single shift vs. multi-shift operations can determine the value of opportunity charging. If the enterprise operates a single shift operation, a fully charged Li-ion (or FLA) battery should power that vehicle through the shift. When a second (or third) shift is needed, then opportunity charging can be used to recharge in increments and ensure that the equipment is powered through all the shifts.
- Rather than charging FLA batteries in a centralized battery maintenance room, distributed the Li-ion charging stations near break rooms and heavy work areas. Decentralized charging stations eliminate the operator’s travel time from their work area to battery maintenance room as well.
- Assess existing FLA chargers to determine if they are compatible with the Li-ion batteries.
- Assess the power output of the existing FLA and Li-ion charging infrastructure. The the power rating on the charger must be much higher when opportunity charging.
- Consider a multi-voltage battery if opportunity charging is desired but there is not adequate down-time within a shift.
SAFEFlex Chargers
The Lithium SafeFlex Battery Charger is designed to operate with Material Handling (MH) and Ground Support Equipment (GSE) Lithium-ion batteries. This charger has universal AC power input, supports full Level 3 charging via a CANBus communications with the battery, has a touchscreen display, provides unity power factor with very low iTHD which results in very high charging efficiency, and has the smallest footprint in the MH and GSE charger industry.
This charger is offered in 15 KiloWatt (kW) and 30 kW models. Each model supports up to three simultaneous charging ports, and performs voltage auto-detect for each of the charging ports. This charger is scalable down to 5 kW and up to 30 kW, while each module has a default power level of 15 kW.
This charger supports local and remote management with an embedded Internet of Things (IoT) processor which provides real-time performance information of each charge session with a Lithium-ion battery. Local support and remote administrative staff can review and manage charger/truck integration and overall fleet performance. Access to the Internet is supported via an Ethernet port, WiFi communications, or GSM cellular communications via Sim card slot.
With this charger connected to our Maestro cloud-based applications, fleet managers can monitor all critical charging performance parameters such as voltage, temperature, charge/ discharge current, charge time connected to the battery, Kilo- Watts delivered per charge session and warnings errors.
Features of SAFEFlex Chargers
- Modular 15 kW and 30 kW models
- Up to three out-puts, 6 different configurations 3 batteries different charged simultaneously
- CANBus communications
- IoT Management via wireless and wired communications
- Real time performance monitoring via Maestro cloud-based application
- Easy configuration via touchscreen display
- Fast charging
- Small and lightweight, high efficiency
- Wall-mounted
Click here to learn more about SAFEFlex Chargers.
Green Cubes Technology Corporation
4124 Cartwright Drive, Kokomo, IN USA 46902
Tel: +1 (502) 416-1060
Email: send an email
Web: www.greencubestech.com
ABOUT GREEN CUBES TECHNOLOGY
Green Cubes Technology develops and manufactures a complete portfolio of lithium power systems that enable its OEM and enterprise customers to transition from Lead Acid and Internal Combustion Engine (ICE) power to Lithium-ion battery power. Green Cubes utilizes proven hardware and software platforms to build the most reliable lithium battery systems in its industries. With over 300 employees across six countries, Green Cubes has been producing innovative, high-performance and high-quality products since 1986. For more information, send an email or visit greencubestech.com.