Driving Fleet Power Productivity with Data: How Battery Modeling Software and Power Management Tools Can Boost Operational Efficiencies

DateMonday, March 28, 2022
Time3:00 PM - 3:45 PM
LocationTheater D

What You Will Learn

With an array of power choices available for today’s industrial fleets – from traditional lead acid batteries to advanced chemistries including Thin Plate Pure Lead (TPPL) and Lithium-ion (Li-ion) – it can be challenging for warehouse managers to determine the solution that’s best for their unique fleet. To improve operational efficiencies and streamline the power selection process, battery manufacturers are developing informational platforms to intelligently analyze operations and quantify specific requirements of the vehicle fleet. By working closely with the customer to support their power demand needs, it may help eliminate unnecessary out-of-pocket costs and unwanted downtime associated with premature battery failure from improper maintenance and charging practices.

For example, sophisticated battery modeling software can help operators make confident, data-driven decisions regarding what power solution – or combination of power solutions – is best suited for their unique fleet. This type of software uses site-specific operational details collected through discussions with the customer to gather data unique to their operation to perform an automated battery performance review. It then generates customized data and actionable intelligence to right-size the customer’s battery and charger fleet. By assessing multiple factors, including the number, size, and type of vehicles in operation, as well as scheduling and charging requirements, this detailed information can help guide proper battery and charger specification and predict potential opportunities for Return on Investment (ROI).

Thanks to the latest virtually maintenance-free TPPL and Li-ion battery technologies, fleet managers can implement a hybrid approach to their warehouse power that can enhance the overall end-user experience and help deliver a lower Total Cost of Ownership (TCO) – no matter the size or scope of the operation.

TPPL technology offers material handlers a reliable power solution without the restrictive upkeep requirements of watering, equalization charging, and battery change outs associated with flooded lead acid batteries. Some designs are even engineered

with a carbon additive for increased cycle life and higher energy throughput. Manufactured with the end-user in mind, they are optimized for fast- and opportunity-charging and are the ideal solution for light- to medium-duty applications.

Ideal for heavy-duty applications, some of the newest Li-ion battery chemistries for material handling vehicles are engineered with sustainable Nickel Manganese Cobalt (NMC) large format prismatic cell chemistry that has been heavily researched and built to deliver high energy capacity in a smaller footprint. With modular construction, the power system is precisely engineered according to operational demand, can maintain a high State of Charge (SOC) because of its speed of recharge capabilities and can be upsized or downsized as demands change.

In addition to innovative battery chemistries, state-of-the-art power management tools can transform battery data into actionable intelligence that protect assets, boost productivity, cut costs and improve operations. For instance, a battery monitoring device, installed directly on the battery cables, communicates with remote sensors on the battery to capture and continuously share vital battery operating data via Bluetooth with customers. A smart battery dashboard, which often features a lift truck-mounted display module, reads data via Bluetooth from the monitoring device to give drivers a live view of key battery operating conditions. Lastly, there are also mobile apps available for free to download, usually for Android™ and iOS® operating systems, that allow users to see and share a range of real-time battery and charger operating data on smartphones or tablet devices for added convenience.

Key Takeaways

? Learn how to forecast long-term power needs, identify operational challenges, and guide the selection of battery technology upgrades to respond to evolving industry demands.
? Discover the latest battery chemistries and power management tools for increased operational efficiency and profitability.


Chris Wayment EnerSys®
Jarrod Smith EnerSys®

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