Lift trucks: With batteries, waste can be too much or too little

Battery management protects equipment, hastens workers and optimizes inventory.

May 11, 2011 - MMH Editorial

For most experienced battery room and lift truck operators, the battery swap process is a cinch. Sure, it can be a pain to take that trip to the far side of the DC, but once there, the process of changing a battery is almost instinctive. Unfortunately, according to Joe Posusney, engineering manager for Philadelphia Scientific, the speed of a battery change is rarely the most important factor, and those instincts are likely a major detriment to equipment health and a serious drain on productivity.

“One customer told me his battery room operators retrieve the battery that feels the hottest, reasoning that it must have the most juice,” says Posusney. “Of course that’s the exact opposite of what you want to do. It’s an old wives’ tale that has no basis in fact. Or they’ll pick the newest battery, whether it’s fully charged or not, expecting better performance from newer equipment. Other times, they just go for the closest battery.”

The result is a battery room where the batteries closest to the front are over-used, a few batteries in the middle are used at roughly ideal intervals and the back half are underused. Battery management software and hardware can eliminate the guesswork by monitoring the state of charge of each battery and directing the battery room operator the optimum battery for each change.

“There is a right battery to take,” says Posusney.

He cited a study of battery performance three months before and three months after the installation of the battery management system. Afterward, batteries produced an average of 30 minutes more operating time per charge. Supplementing this increased productivity is a free, Web-based software that tracks the usage of each battery and can generate a variety of reports in an instant.

Combined with hardware that can help identify whether a battery is connected in the first place or whether the charger cable is even functional, such systems allow an organization to right-size their battery inventory.

“Waste can be too many batteries or too few,” says Posusney. “You always want to optimize. This system keeps assets in play.”

Fast-charge or opportunity charge setups would benefit little from this sort of battery management, says Posusney, but depending on the scale of an operation and the customized blend of software and hardware, battery management systems can generate returns in as little as seven months.



Subscribe to Modern Materials Handling magazine

Subscribe today. It's FREE!
Find out what the world's most innovative companies are doing to improve productivity in their plants and distribution centers.
Start your FREE subscription today!

Recent Entries

Despite advances in process automation, vital business processes consisting of data-driven tasks such as collecting, reviewing, and inputting information still exist in most organizations. These tasks are mundane, repetitive and... okay, boring.

Pressure-senstitive labeling machinery company expands Accraply's products and markets.

The new tire handling systems group will offer a variety of services including design engineering, project management, site supervision, controls, software, automated storage and retrieval, and custom manufacturing solutions specific to the tire industry.

New facility to house more than 300 engineers, project managers, sales, customer service and administrative staff.

Material handling parts distributor acquires Mid-Atlantic industrial safety distributor.

About the Author

Josh Bond, Contributing Editor
Josh Bond is Senior Editor for Modern, and was formerly Modern’s lift truck columnist and associate editor. He has a degree in Journalism from Keene State College and has studied business management at Franklin Pierce University.

Comments

Post a comment
Commenting is not available in this channel entry.