Industry solution: AGV, AGC & heavy-duty
Lithium batteries for AGVs – move 40 tonnes cable-free, precisely and reliably.
Custom lithium batteries for automated guided vehicles (AGV) and driverless transport systems up to 40 tonnes – where standard batteries gave up long ago.
Request a free initial assessmentThe challenge
Extreme power
Moving up to 40 tonnes autonomously – no off-the-shelf battery delivers enough energy in such a small space.
Tightest space constraints
There is not a millimetre to spare inside the vehicle – battery and enclosure have to fit exactly.
Worldwide AGV operation
AGVs from Japan through Europe to the USA – the battery system has to work reliably everywhere.
Our solution
Developed together with Georg Kramp – for the ROBOT-40, an autonomous heavy-duty transport system.
Two custom lithium batteries
Sized on the exact energy demand for moving 40 tonnes precisely and safely.
Purpose-built enclosure
Despite the tightest space inside the ROBOT-40 – a perfect-fit integration, never an off-the-shelf product.
Battery-swap system
An enclosure developed with partner companies for fast battery swaps and maximum operational flexibility.
Matched chargers
A complete system of battery and charger – perfectly matched to one another for the overall system.
Customer story
Georg Kramp GmbH – ROBOT-40
Since 2013, Hellpower Energy has maintained a close partnership with Georg Kramp GmbH – a heavy-duty logistics specialist that carries out special relocations and large industrial transports of up to 40 tonnes worldwide.
Georg Kramp GmbH was developing an autonomous transport system for heavy machinery – and found no battery solution that met these requirements: lead was too big, too heavy or too weak for the required performance in such a confined installation space.
Hellpower Energy developed two custom lithium batteries with a purpose-built enclosure – to this day no standard battery fits the vehicle, because space and power demands are so specific that the solution remains unique.
The ROBOT-40 is deployed worldwide – from Japan through Europe to the USA – wherever large machines must be moved autonomously under tight or sensitive conditions.
Requirement · Solution · Result
Requirement: Autonomous transport system for heavy loads up to 40 tonnes – cable-free operation, extremely tight packaging inside the vehicle frame, worldwide deployment under varying environmental conditions.
Solution: Two custom-built lithium battery packs with purpose-fit steel enclosures, a matched charger and a fast-swap battery carrier system – developed in close collaboration with Georg Kramp and partner companies.
Result: ROBOT-40 in series operation since 2013 – not a single off-the-shelf product fits the vehicle to this day. Reliable operation confirmed on four continents.
With Hellpower we finally found a partner who not only supplies batteries but truly understood our challenge. Our application was too specific for standard solutions – and Hellpower developed a solution that fits exactly. This was not a supplier relationship – it was a real development partnership.
Managing Director, Georg Kramp GmbH & Co. KG
Your benefits
1
Dedicated contact person
40 t
Transport capacity
✦
Custom-built battery
Frequently asked questions
- Which cell chemistry is recommended for AGVs – LiFePO4 or Li-NMC?
- For industrial AGV and FTS applications, LiFePO4 (lithium iron phosphate) is the predominant choice. It offers thermal stability, a high cycle life and is less sensitive to mechanical stress. Li-NMC is considered when energy density in a very tight installation space is the overriding factor and thermal management is engineered accordingly.
- Can a custom AGV battery communicate with our PLC control system?
- Yes. Hellpower has delivered AGV battery packs with Profinet connectivity that transmit state of charge, current, voltage and temperatures in real time directly to an industrial PLC (e.g. S7 environment) – without an additional gateway. CAN-Bus and SMBus are also available as BMS communication interfaces.
- How is the battery pack adapted to the exact space constraints inside the AGV?
- After recording the installation dimensions and load requirements, a purpose-fit enclosure is engineered – including brackets, cable routing and, if required, a swap system. Off-the-shelf products typically do not fit special-purpose vehicle frames; Hellpower supplies exclusively custom-built packs.
- Which IP ratings and certifications are relevant for AGV batteries?
- Depending on the operating environment, relevant requirements include IP protection ratings (e.g. IP54 or higher), CE conformity under the Low Voltage Directive and UN 38.3 for hazardous goods transport. In food or pharmaceutical AGV applications, ATEX requirements may also apply. Hellpower advises on the appropriate certification strategy for each application.
- From what production volume does a custom battery pack make economic sense?
- Custom battery packs are viable even at low volumes when standard products do not fit mechanically or electrically. The decisive factor is not volume alone, but whether total costs – integration effort, downtime and service – are lower with a custom solution over the product lifecycle.
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Battery know-how
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Updated
Ready for a battery solution that moves 40 tonnes?
We develop custom lithium batteries for your AGV and heavy-duty application – field-proven and one of a kind.
Request a free initial assessmentOr call us directly: +43 2265 20775 0