Lithium batteries for intralogistics – when the power runs out, the warehouse stops.

The challenge

Frequently asked questions

How long does a lithium battery for mobile workstations last in warehouse operation?

The battery boxes delivered by Hellpower in rugged Peli Cases achieve runtimes of up to 7 days in real multi-shift operation – depending on connected loads (scanner, printer, industrial PC). This is a significant improvement over conventional lead-acid batteries, which typically last 2–3 days.

Can lithium batteries replace lead-acid batteries in existing forklifts and industrial trucks?

In most cases yes. Lithium batteries are significantly lighter, charge faster (opportunity charging) and eliminate the need for cumbersome battery swaps. Hellpower checks installation dimensions, voltage levels and charger compatibility – and provides a matched complete system if required.

What voltage levels and capacities are typical for AMR batteries?

Common voltage levels for AMRs and AGVs are 24 V, 48 V and 72 V – capacities range from 20 Ah to 200 Ah depending on vehicle class and shift length. Hellpower sizes packs based on actual load profiles and installation dimensions. Example from customer deployment: 24 V/60 Ah for AMRs in order-picking operation.

How is the battery replaced during ongoing warehouse operation if it fails?

Hellpower designs battery systems with fast replacement in mind – swap systems without special tools, standardised connectors and clear status indicators via the BMS. The Peli Case battery box requires no tools; for fixed-mounted packs the swap concept is defined during engineering.

Is the battery box suitable for cold-store or deep-freeze operation?

LiFePO4 cells operate in a range of approximately –10 °C to +55 °C (in use). For deep-freeze areas below –10 °C, a heating foil inside the battery pack is required so that the BMS protects the cells and releases charging only at sufficient temperature. Hellpower advises on the appropriate configuration.