Big ideas for lift truck batteries

This started as a story about lift truck batteries. That lasted about 45 seconds. That’s when Damon Hosmer of Raymond said: “Don’t forget about hydrogen.”

Lead acid still accounts for probably 80% or more of all batteries. Lithium-ion is moving up to 15% or more. That leaves the balance for hydrogen as a power source. At less than 5%, that’s not a lot, but it’s worth noting. It also offers the chance to start to change the conversation from purely batteries to lift truck power management.

With that out of the way, this is still very primarily a story about batteries. A more in-depth look at hydrogen will have to wait for another day.

Meanwhile, here are three reports to help make you, your batteries and your relationship with the power grid a little bit more energized.

Start with the big picture: Power technology selection

Selecting batteries and managing a charging room are key steps to success with lift truck power management. But a recent discussion with Crown Equipment’s general manager of motive power, Trevor Bonifas, makes it clear that some time must be spent on the big picture of powering lift trucks.

Bonifas looks first at power technology selection. Traditional lead acid has been joined by thin plate pure lead (TPPL) as well as lithium-ion (Li-ion) and hydrogen.

All are in play. And you have to decide which is best suited to each function in your operation.

Each option has strengths and weaknesses. And those need to be compared to the demands of your operation. For instance, what’s your facility’s throughput? And, what’s its fleet mix of makes and models? You also need to review safety practices and workforce habits to accommodate different charging demands of the various battery types.

This last item brings up another of Bonifas’ key points: understand your commitment to making the selected technology work. This includes space and budget resources as well as workforce attention to managing batteries day in and day out.

It’s worth noting that lead acid batteries require inspection and watering at the proper times as well as proper charging habits and routine maintenance on cables and connectors. With lithium-ion batteries, it’s important to opportunity charge multiple times daily. That requires placing chargers and charging stations in advantageous locations. It’s also important to pay attention to wear and tear on frequently used cables and connectors.

You will also need to manage your infrastructure costs, says Bonifas. This requires an awareness of your utility’s peak electricity usage times and how they align with your charging requirements. As electricity costs climb at peak demand times, opportunity charging is most cost efficient when scheduled outside those times. A list of optimal charge times during the day helps operators get it right, says Bonifas.

In addition, high frequency/high efficiency chargers help reduce costs.

Bonifas also strongly suggests using telematics data to leverage power equipment buying and use decisions. He recommends continual monitoring of all assets involved as well as the people.

“Operations managers should always be evaluating how they are using power and considering ways to make better use of it. You only want to take from the grid what is absolutely required,” Bonifas says.

While this is a quick list of helpful hints to make power decisions, Bonifas offers his most important bit of advice: “Be curious. Ask questions. Challenge suppliers. Recognize that you know more about your operations than anyone else. Their expertise is in providing solutions and after sales and service that best meet your needs.”

How to run a tight battery management room

Plenty of ways can be found to be less than efficient and safe in a lead acid battery room. You may even have a couple of personal favorites.

Fortunately, Damon Hosmer, Raymond’s general manager of energy management solutions, has four time-proven points of interest for being more efficient.

1. By the rules training & certification

People need to be knowledgeable about all types of equipment in the battery room, says Hosmer. This includes extraction systems, charging equipment, watering systems, safety systems, and, of course, the batteries themselves.

Knowledge here includes not just information about operation of the equipment but of proper safety procedures and appropriate emergency responses.

Hosmer strongly advises building prescribed handling practices in the battery room around specific industry-accepted safety certification.

2. Regular inspection & maintenance of battery room equipment

No piece or type of equipment is too insignificant to be overlooked here. And Hosmer says “regular” can start with daily inspection of equipment just to ensure it’s all in good operating order.

In addition, “regular” can be expanded out to quarterly when it comes to maintenance. In other words, preventative maintenance of battery room equipment, just like lift trucks themselves, is a better approach than waiting for something to fail.

That said, Hosmer points out that different types of equipment operate on different cycles. As a result, “regular” can take on its own meaning depending on frequency of equipment use.

3. Proper battery charging practices

Every battery room needs pre-set procedures and practices, asserts Hosmer. And they need to be followed.

Ultimately, the battle is to get the longest life out of each battery, and they are all individuals, to maximize the investment up front. This is especially important when charging in the same room both traditional lead acid batteries and thin plate pure lead design. They are different and require different practices.

4. Use of data beyond signage & labeling

Hosmer is not downplaying proper signage and labeling here. He’s just saying those are not the only data needed in the battery room.

Additional data points he mentions are far ranging.

Points include what he calls power consumption economics, correlating the power consumed from the grid to the fleet size to ensure batteries are not overcharged.

Also on the list is tracking inspection and maintenance of each piece of equipment to maximize its useful life. For instance, tracking data is critical to actually getting 10 to 12 years from a charger or 1 to 2 years from a watering system. Not to mention 5 to 6 years from each battery.

Hosmer says it’s important to remember that the battery room and equipment in it is actually an ecosystem that is best served by a holistic approach to its use and operation.

While those are Hosmer’s top four points of interest, he has others worth noting.

Precise temperature control of the battery room is one of them. Hosmer says it should always be in a range of 68 to 77 degrees to prevent accelerated dehydration. Proper ventilation of the room fits right in here, too.

Electrical standards are critical. This requires all wiring to be properly insulated and grounded. If there is a malfunction, Hosmer says, immediately go to Lock it Out, Tag it Out to reduce risks and malfunctions.

Spill containment also makes the list. He recommends generous use of spill containment pallets, trays and drip pans. Also, an acid-resistant floor coating can be a great investment.

To finish off the list, Hosmer mentions availability of personal protective equipment as well as emergency procedures and equipment.

As a final recommendation for running a tight battery management room, Hosmer says to design it “creatively and eloquently. What’s been done for decades doesn’t have to be repeated again. It’s worth the investment to support your people and equipment in the best way possible.”

Tips on moving to lithium-ion batteries

So, you’re thinking about adding lithium-ion batteries to your lift truck fleet. A lot of operations are doing the same. Some are going all in, but others will run a hybrid fleet with lead acid batteries in some trucks.

Regardless, the switch requires some serious up-front planning and education. Just ask Phu Tran, director of product marketing at lithium-ion battery supplier Inventus Power. Here are his top thoughts on making the shift.

To begin, lithium-ion batteries have their own set of regulations for shipping and handling in transit. And while your supplier will be responsible for that, it’s an important distinction that underscores how different they are from lead acid.

Then you need to look at the charging room. Or lack thereof, as Tran points out.

Lead acid batteries require a dedicated charging room. The charge cycle runs 8 hours and more, including outgassing.

Lithium-ion is nothing like that, says Tran. Rather than a charging room, lithium-ion charge three to five times faster and can be opportunity charged at dedicated stations scattered around the facility. Charge times can be as short as a scheduled driver break.

But as Tran points out, opportunity charging does require some change of habits by drivers.

No longer is it best to run the truck all shift without charging. Instead, operators can charge the batteries during their shift to keep it at top performance. And perhaps just as important, the battery is generally well charged at the end of the shift, ready for the next immediately.

You’ll also need to consider an intelligent battery management system. It allows full, integrated monitoring of each battery for voltage, temperature, current, remaining capacity, battery health and total consumed energy.

If you keep lithium-ion batteries in reserve, they do require special storage, unlike lead acid. Lithium-ion batteries need to be stored in a climate-controlled room in accordance with your local regulations. There are limitations as to how many can be stored in a given square footage, adds Tran.

His advice on moving to lithium-ion is straightforward:

• Do your homework to understand your system, operational requirements and goals;
• Prepare your facility to properly manage and store lithium;
• Educate your workforce on the use and benefits of lithium; and
• Change people’s mindset from traditional lead acid battery management and service.

Tran’s final words of wisdom: “Don’t be afraid to change.”