More power to you

In a tough working environment such as the modern warehouse then fleet managers must weigh up many different factors when looking to upgrade their trucks, of which choice of battery is a major consideration.

Before introducing lithium-ion battery technology, customers must understand what they need from their application in terms of utilisation, shifts and working hours, breaks for opportunity charging and seasonal fluctuations. And they also must ensure their electrical infrastructure and power supply can provide the energy required by the chargers. As lithium batteries can be charged more quickly, this shorter charging period results in a higher energy requirement (dubbed "peak load"). 

The customer must therefore check:

• a) whether the total energy requirements for all their chargers can be provided by the energy supplier or whether there are any restrictions; and 
• b) whether the electrical equipment at the individual charging points is sufficient for the requirements of a single charger.

To support the customer in this early stage of planning, Crown is the ideal partner. The company works with its customers on site, helping them better understand their logistical processes and applications in detail. Crown also helps assess the necessary energy infrastructure so it can develop tailor-made solutions for optimal efficiency. If necessary, Crown technicians will carry out "power studies", in which recording devices are run on existing forklifts to determine the exact energy requirements of the equipment and the time needed for optimal charging. When the applications have been clearly defined, Crown will select the most suitable battery/charger combination, thereby saving the customer money by preventing them from investing in an unsuitable battery for their needs.

While lead-acid batteries require lower investment and might be seen as a better alternative for certain applications, for example light applications, already existing charging infrastructure or low energy availability, lithium-ion systems offer considerable advantages, especially in multi-shift operation. Routine battery maintenance is no longer necessary, and batteries no longer need to be changed or watered, resulting in lower operational and service costs, higher truck availability and minimised accident risks. As lithium-ion batteries do not produce emissions while recharging, separate battery-charging rooms are no longer required.

Opportunity charging

Another big advantage is the ability of lithium-ion batteries to be opportunity-charged during operator breaks, without adversely affecting battery life. Every minor work interruption can therefore be used for charging, no matter how full the battery is at that moment or how short or long the charge is – many small charges even extend the life of the battery. This opportunity charging can help achieve much longer run times and removes the need for unnecessary battery changing. 

The energy efficiency and durability of lithium-ion battery systems is considerably higher and due to fast charging opportunities, batteries of lower capacity are sufficient for the same application compared to lead-acid batteries. Batteries can be fully charged in a short time (with V-Force in only 60 minutes) – instead of the 8 to 12 hours required by lead-acid and without the need for cool-down periods after charging.

Crown has introduced the V-Force Lithium-Ion ESS across its complete range of forklifts to help customers using alternative energy-powered forklifts achieve lower operational costs, enhance productivity and efficiency. The components of the V-Force ESS include a lithium-ion battery pack, a compatible V-Force charger and a fully integrated battery management system. This has been designed to extend battery life by preventing operation outside of warrantied conditions.

The ability to rely on one trusted supplier for forklift truck, battery and charger technologies is essential, helping to offer fleet managers peace of mind when choosing a truck upgrade. Therefore, all Crown’s V-Force Lithium-Ion Energy Storage Systems are being sold and supported through Crown’s extensive global retail network as part of Crown’s complete material handling solutions. In addition, the whole system is backed by Crown’s comprehensive service and support network. This means highly qualified service technicians can visit customers’ premises to help ensure forklifts, chargers and batteries are in proper operating condition. 

Cost-efficient operation will be a major consideration for fleet managers, which is why all V-Force batteries and chargers are also available under a rental plan.

Other factors such as reliability and practicality will be considerations for fleet managers. Crown’s V-Force batteries are designed to meet the highest automotive standards in terms of safety, ease of use and durability. As such, they offer more capabilities than many other lithium-ion batteries on the market. 

Fitted with multiple redundant safety systems, each battery features a multi-level safety architecture incorporating, for example, a variety of fuses plus single-cell temperature and voltage monitoring. Safety systems built into the battery help protect against overheating, short circuits, overcharging or deep discharging. 

Crown’s V-Force V-HFB Series high-frequency chargers have been purposely designed to deliver the power a lithium-ion energy storage system needs. Crown’s V-Force Energy Storage Systems (ESS) include lithium-ion batteries and chargers and are now available for Crown’s entire forklift truck portfolio.

The performance of the Crown chargers is excellent thanks to the fast charging process, meaning truck availability is increased and productivity levels can be maintained without any interruptions. V-Force chargers use resonance-frequency technology to achieve charging rates of up to 1C. This means they can fully charge batteries with capacities of up to 400 Ah in less than 60 minutes by delivering a steady charging current of up to 400 A. These figures are among the best in the industry. 

The user-friendly chargers can handle battery voltages ranging from 24 to 80 volts. To detect each battery’s voltage class automatically and charge the battery without requiring manual pre-sets, the charger communicates directly with the battery management system via the CAN bus. An intuitive touchscreen displays a clear overview of the battery’s charging and operating status.

With Crown V-Force Energy Storage Systems and comprehensive consulting services, companies choosing lithium-ion technology are in safe hands.

For more information, visit www.crown.com/en-uk