Analysis Series, Chapter 5: Voltage Levels Used in Electric Lift trucks Today

by | Aug 18, 2022 | Forklift Fleet Management | 0 comments

Chapter 5: Voltage Levels Used in Electric Lift trucks Today

Electric warehousing lift trucks are based on a range of voltages (e.g. 24V, 36V, 48V and 80V). Some applications don’t require a great deal of power. For example, most Class III lift trucks (walkies, walkie-stackers and walkie end-riders) operate on 24V power, considered a low voltage. Smaller lift trucks like these often (although not always) only have to transport lighter loads, have limited hydraulic functions requiring lower amperage and work in areas where top speeds are not important. With a relatively low voltage and lower amperage, power output is low. On the other hand, a higher voltage in a truck’s electrical system means the ability to achieve higher levels of performance. For example, an 80V system, as opposed to, say, a 36V system, permits higher levels of acceleration and torque.

In general, any current flow entails some heat radiating from conductors. Thus, the low current of a higher voltage system means relatively lower heat losses. In a lift truck, the single biggest enemy of energy efficient operation is buildup of heat that cannot be dissipated quickly. Heat buildup not only harms electronic components, it also creates greater electrical resistance in wiring and cables, making it more difficult for a battery to push current through the conductors – as the electrical resistance has been increased. A rising heat level in conductors means a greater current draw is needed to compensate for this increased resistance, which in turn creates even more heat.

Continue to Chapter 6…

Read The Full Series:

Chapter 1: The Concept of Total Cost of Ownership (TCO)

Chapter 2: AC Technology Compared to Internal Combustion

Chapter 3: Compressed Natural Gas (CNG)

Chapter 4: Trends in Materials Handling

Chapter 5: Voltage Levels Used in Electric Lift trucks Today

Chapter 6: Battery and Charging Systems

Chapter 7: Electric Braking and Energy Regeneration

Chapter 8: Emissions and Corporate Responsibility: A Major Problem for IC Lift Trucks

Conclusions & Final Recap

HCO Innovations is publishing this eight-part series as an in-depth comparative analysis and discussion on Compressed Natural Gas (CNG) Internal Combustion (IC) motors and Alternating Current (AC) Eletric lift truck engines, Comparison Analysis of CNG (IC) vs. AC Electric Lift Trucks, by Will Van Ness, VP of Fleet Management at HCO Innovations

Comparison Analysis of CNG (IC) vs. AC Electric Lift Trucks (AC)

The materials handling industry continues to evolve at a rapid pace, particularly in the area of motive power propulsion. Tremendous technological advancements have been made over the past decade to directly address the rising cost of petrol (fossil fuels) along with stricter emission standards. Today’s MHE acquirers have more choices than ever when it comes to motive power propulsion and with the success seen amongst fleets utilizing alternative fuel sources such as lithium ion (LION) and Hydrogen Fuel Cell (HFC), the choices will most likely increase as time goes on. For the purpose of this discussion document, our focus will be on comparing AC Electric (AC) to Internal Combustion powered lift trucks (IC), specifically compressed natural gas (CNG).

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What are the voltage levels commonly used in electric lift trucks today?

Electric lift trucks commonly use voltage levels ranging from 24V to 96V. The specific voltage level depends on the size, capacity, and usage requirements of the lift truck. Higher voltage levels are typically found in larger and heavier lift trucks.

What are the advantages of using higher voltage levels in electric lift trucks?

Higher voltage levels in electric lift trucks offer several advantages. They provide increased power and torque, resulting in faster acceleration and improved performance, especially while lifting heavy loads. Higher voltage systems also allow for longer operating runtime and reduced charging times compared to lower voltage systems.

Are there any disadvantages of using higher voltage levels in electric lift trucks?

While higher voltage levels bring many advantages, there are a few potential downsides to consider. Higher voltage systems often require larger and heavier batteries, which can impact the overall weight and maneuverability of the lift truck. Additionally, higher voltage systems may have stricter safety regulations and require specialized training for maintenance and operation.

Can electric lift trucks with different voltage levels be used interchangeably?

No, electric lift trucks with different voltage levels are not interchangeable. Each lift truck is designed to work with a specific voltage level, and using the wrong voltage can result in system damage or reduced performance. It is important to ensure that the voltage level of the lift truck matches the charging infrastructure and any other related equipment.

How can I determine the right voltage level for my electric lift truck?

The right voltage level for your electric lift truck depends on various factors, including the application, load capacity, and operational requirements. Consulting with the lift truck manufacturer or a qualified industry expert is recommended to determine the appropriate voltage level for your specific needs.

What are the maintenance considerations for electric lift trucks with higher voltage levels?

Electric lift trucks with higher voltage levels typically require specialized maintenance procedures. It is crucial to follow the manufacturer's guidelines for battery maintenance, including regular inspections, proper charging techniques, and ensuring that the battery remains within the optimal voltage range. Consulting the manufacturer or an authorized service provider for maintenance advice is highly recommended.

Unique Applications of Electric Lift Trucks in the Warehouse Environment

When it comes to optimizing warehouse operations, choosing the right equipment can make a significant difference. One type of equipment that has revolutionized the warehouse industry is electric lift trucks. These versatile machines are not only environmentally friendly but also offer unique applications that can enhance efficiency and productivity in the warehouse environment.

1. Versatility in Narrow Aisles

One of the main advantages of electric lift trucks is their ability to operate in narrow aisles. Traditional forklifts require wider aisles for maneuverability, limiting the storage capacity within a warehouse. With electric lift trucks, however, the compact design and exceptional maneuverability allow them to navigate through narrow spaces, maximizing the use of available storage area.

In addition to narrow aisle operation, electric lift trucks also offer other features that enhance versatility, such as the ability to rotate the forks to handle different types of loads, including pallets, drums, and even specialized containers. By utilizing electric lift trucks with rotating forks, warehouses can eliminate the need for additional equipment and simplify their operations.

2. Enhanced Safety Features

Safety is a top priority in any warehouse environment. Electric lift trucks are designed with advanced safety features that help minimize the risk of accidents and injuries. These features include stability control systems, speed reduction in corners, and automatic braking systems.

Furthermore, electric lift trucks produce zero emissions, creating a safer work environment by reducing exposure to harmful fumes. This is especially important in industries where hazardous materials are handled, such as food processing or chemical manufacturing. With electric lift trucks, warehouses can ensure the safety and well-being of their employees while maintaining compliance with environmental regulations.

3. Energy Efficiency

Electric lift trucks are highly energy-efficient compared to their internal combustion counterparts. They are powered by rechargeable batteries, which are not only more cost-effective but also produce lower noise levels during operation. This makes electric lift trucks ideal for warehouses located in urban areas or those with noise restrictions.

Furthermore, the energy efficiency of electric lift trucks translates into reduced operating costs. Compared to traditional forklifts running on fossil fuels, electric lift trucks have lower maintenance requirements and lower fuel costs. Additionally, many companies offer innovative battery management systems that optimize the charging and usage of batteries, further maximizing the efficiency of electric lift trucks.

4. Improved Ergonomics

Warehouse operators spend many hours operating lift trucks, which can take a toll on their physical well-being. Electric lift trucks are designed with ergonomic features that prioritize the comfort and safety of operators during long shifts.

These features include adjustable seating positions, intuitive control layouts, and noise reduction technology. By providing a more ergonomic working environment, electric lift trucks help reduce operator fatigue and minimize the risk of musculoskeletal injuries.

5. Cost Savings

Implementing electric lift trucks in a warehouse operation can result in significant cost savings. These savings come from various factors, including reduced maintenance costs, lower fuel expenses, and potential tax incentives or grants for implementing eco-friendly equipment.

Additionally, electric lift trucks have a longer lifespan compared to internal combustion forklifts. With regular maintenance and proper battery management, electric lift trucks can last longer, resulting in higher return on investment for warehouse operators.

Overall, the unique applications of electric lift trucks bring numerous benefits to the warehouse environment. From improved efficiency and productivity to enhanced safety and cost savings, these innovative machines are transforming the way warehouses operate.

If you are looking to optimize your warehouse operations and reduce material handling costs, HCO Innovations can help. With our expertise in warehouse optimization and forklift fleet management, we offer comprehensive solutions tailored to your specific needs. Visit our websiteHCO Innovationsto learn more about how we can help you enhance your warehouse operations and drive greater success in your business.

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