A forklift battery power study is an essential tool for businesses looking to improve efficiency, reduce costs, and optimize their material handling operations. By analyzing how your lift trucks use energy, you can make informed decisions about battery management and charging technology. This guide breaks down the key objectives and processes of a forklift battery power study.

Site Study Objectives

A comprehensive power study focuses on several key areas to provide a complete picture of your fleet’s energy needs.

• Vehicle Battery Usage: The study’s primary goal is to capture vehicle battery usage in terms of Equivalent Battery Units (EBU). One EBU equals 80% of the battery’s nameplate capacity. This metric provides a standardized way to measure actual energy consumption, helping to determine if your current batteries are properly sized for the workload.

• Opportunities for Charging: The study monitors and records opportunities for charging, specifically focusing on idle time. Idle periods, which often occur during breaks, shift changes, or lulls in production, are perfect windows to “opportunity charge” and extend battery life.

• State of Charge (SOC) Analysis: Based on the data, the study determines if it’s feasible to keep the battery SOC between 80% and 20% daily. This range is crucial for maximizing battery health and lifespan. Operating outside this range (e.g., constantly deep discharging to below 20%) can cause irreversible damage.

• Weekly Equalization (EQ) Charge: The study also analyzes whether there’s sufficient time to perform one weekly EQ charge cycle. An equalization charge is a controlled overcharge that helps balance the voltage across all battery cells, preventing cell stratification and prolonging the battery’s service life.

• Best Charging Technology: Ultimately, the study determines what type of charging will work best for your specific operation. The data collected provides the foundation for a tailored recommendation, whether it’s traditional charging, opportunity charging, or high-frequency charging.

The Ametek Site Probe Power Study
Understanding your lift trucks’ operational patterns is a critical first step. A power study with the Ametek Site Probe provides the necessary data to make informed decisions.

A specialized device called the Site Probe is temporarily installed on a representative lift truck. This device collects data on battery usage, idle time, current draw, and battery voltage over a one- to two-week period. The collected data, along with insights from operator and management questionnaires, is then analyzed to create a detailed report.

This analysis provides the foundation for a system recommendation, ensuring that the charging technology and battery management practices you adopt are perfectly suited to your unique operational demands.