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How to choose the right electric forklift battery based on application scenarios?

2025-11-14 Visits:

Core Logic for Selecting Electric Forklift Batteries

The core logic for choosing electric forklift batteries lies in matching based on four dimensions: "usage duration, operation intensity, environmental conditions, and budget". For single-shift low-intensity operations, lead-acid batteries are preferred; for multi-shift high-intensity operations or special environments, lithium iron phosphate (LFP) batteries are the choice.

Core Logic for Selecting Electric Forklift Batteries

I. Core Judgment Dimensions (Clarify Your Own Needs First)

  • Daily Operation Duration: ≤ 6 hours (single shift), 6-10 hours (double shifts), ≥ 10 hours (multiple shifts)
  • Operation Intensity:
    • Intermittent operation (e.g., small warehouses)
    • Continuous high-frequency operation (e.g., logistics sorting)
    • Heavy-load climbing (e.g., heavy goods handling in workshops)
  • Environmental Conditions:
    • Normal temperature (0-35℃)
    • Low temperature (≤ 0℃, e.g., cold storage)
    • Humid/dusty environment (e.g., outdoor freight yards)
  • Budget Priority: Priority on initial investment, priority on long-term operating costs

II. Typical Scenarios and Battery Matching Solutions

Application ScenarioRecommended Battery TypeKey Reasons
Small warehouses / Single-shift operations (4-6 hours per day)Lead-acid batteries (AGM / Flooded)Low initial cost, simple maintenance, meets basic endurance needs, and offers the highest cost-effectiveness.
Medium-sized warehouses / Double-shift operations (8-10 hours per day)Lithium iron phosphate (LFP) batteriesSupport fast charging and opportunity charging, no need for battery replacement, reducing downtime.
Logistics centers / Multi-shift high-frequency operations (≥ 10 hours per day)Lithium iron phosphate (LFP) batteriesLong cycle life (over 3,000 cycles), zero maintenance, and lower total cost of ownership (TCO) in the long run.
Cold storage / Low-temperature environments (-20℃~0℃)Lithium iron phosphate (LFP) batteriesHigh low-temperature capacity retention rate (over 70%), while lead-acid batteries only have about 50%, avoiding sudden endurance ｄｒｏｐ.
Outdoor / Humid and dusty environmentsSealed lithium iron phosphate (LFP) batteries / AGM lead-acid batteriesSealed design prevents liquid leakage and corrosion, no need to worry about environmental impacts.
Limited budget / Short-term use (≤ 3 years)Flooded lead-acid batteriesLowest entry cost, mature maintenance process, suitable for temporary transition or low-frequency use.
Heavy-load forklifts (> 5 tons) / Frequent climbingLithium iron phosphate (LFP) batteriesHigh energy density, stable discharge, and can continuously provide the power required for heavy loads.

III. Three-Step Practical Selection Process

  1. Determine Battery Voltage (Match Forklift Model)
    • Light-duty forklifts (≤ 2 tons): 24V / 36V
    • Medium-duty forklifts (2-5 tons): 48V
    • Heavy-duty forklifts (> 5 tons): 80V
  2. Calculate Required Capacity (Avoid Insufficient Endurance)
    • Simplified formula: Capacity (Ah) = Forklift operating current (A) × Daily operation duration (h) ÷ Depth of discharge (DOD) coefficient
    • DOD for lead-acid batteries: 50%-60%
    • DOD for lithium iron phosphate batteries: 80%-90%
    • Example: For a 48V forklift with an operating current of 100A and 8 hours of daily operation, the required lithium battery capacity is 100×8÷0.8 = 1000Ah.
  3. Lock in Battery Type Based on Scenarios (Refer to the Matching Table in Step II)

IV. Key Considerations

  • Prioritize Total Cost of Ownership (TCO): Lithium batteries have a higher initial price, but their TCO over 10 years is 40% lower than that of lead-acid batteries, making them more cost-effective for high-frequency use.
  • Match Forklift Manufacturer's Requirements: Avoid voltage/interface incompatibility. Some forklifts require a dedicated Battery Management System (BMS).
  • Pay Extra Attention to Special Needs: For low-temperature environments, ｓｅｌｅｃｔ "low-temperature adaptive lithium iron phosphate batteries"; for outdoor operations, confirm the battery protection level (IP65+ is better).


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