Which system of battery replacement should you choose?

Choosing the right solution depends on many factors. In order to make the right choice you can base on four main criteria: the costs, the height of the ceiling in the charging room, room size, efficiency / productivity.

The costs

Often, many solutions will be rejected from the outset, because knowing the size of our budget, we understand what we can afford. That’s why this criterion is on the first place. We will not be able to install the most advanced automated system of battery replacement, with a budget that will allow us to purchase only handcarts. However, on the other hand, the right choice of solution affect the substantial cost savings by speeding up the replacement of the batteries, improvement the organization of work and the use of batteries.

Ceiling height

This option also can quickly limit our choice of possible solutions. It is assumed that the height of the ceiling determines the use of specific solutions depending on the number of batteries storage levels :

  • One-level system – 3,60m
  • Two-levels system – 4,80m
  • Three-levels system – 6,00m
  • Four-levels system – 7,20m
  • The system of five levels – 8,40m
  • The system of six levels – 9,60m

The size of the room. It is assumed that the system increase by one level allows to save the area by 17%. This option is especially important for companies that use high-bay warehouses and know that every square meter worth its weight in gold.

Efficiency / Productivity

One of the most common reasons due to which the company decides on the use of battery replacement systems is the reduction of time for battery replacement. By reducing the waiting time of forklift truck for replacement of the battery, we increase at  the same time the productivity. Increased productivity is probably one of the most important areas on which the company should focus. However, certain threats could appear. By increasing the height of the batteries levels, we can lose the time saved by using a battery replacement system, as the battery replacement system behaves like a forklift truck that moves goods faster forward than raises them up. It should be noted that very often you can find the information in the documentation of such systems about the reduction of speed machine on different heights. It is also necessary to take into account another important argument – at a very high level of the system it can be difficult to remove a battery during the service or repair of the machine.

To illustrate the mentioned above, let’s give an example. Suppose we have 200 batteries. In this case, depending on the chosen system at the lowest level, in case of failure of the machine, we have the following number of batteries, as presented below.

Types of systems and the number of available batteries:

  • One-level system – 200 pcs.
  • Two-level system – 100 pcs.
  • Three-level system – 67 pcs.
  • Four-level system – 50 pcs.
  • The system of five level – 40 pcs.
  • The system of six level – 34 pcs.

Taking into consideration that on average 50% of the available batteries are in charge mode, it can be seen that most of large battery fleets will not be able to work for a long time with such a small amount of batteries that are available in an emergency mode. Therefore, based on the above, and on the fairly short charging time, it can be assumed that the table below will help you to choose the battery replacement system considering the number of available batteries.

The quantity of stored battery and the type of system

  • 1-49- one-level system
  • 50-139 two-level system
  • 140-299 three-level system
  • 300-619 four-level system
  • 620+ five-level system

And what about smaller battery fleets?

We shouldn’t forget that not everyone needs a big battery replacement system, because not all are working in three shifts with full use of two or sometimes even three batteries. In the end, there are battery fleets which consist of several or a dozen trucks in which it is necessary to use mechanical means to replace the batteries, as it require the labour legislation or other regulations. One of such regulations is the Decree of Ministry of Labour and Social Policy of Poland concerning the safety and health at work using manual transport. The Decree determines the conditions of transportation of goods, as well as batteries. To fulfil the requirements, which are presented in this document, it could be used, for example, the pad on the forklift, that allows to remove the battery from another truck without any effort from the operator. This is one of the cheapest and simplest solutions on the market.

You can use a trolley with batteries of low weight up to 250-300 kg. The trolley will move along one-level battery rack and will allow to place the battery on the rack. The trolley has two battery compartments. Each compartment has the ability of independent regulation of the height and has a manual drive. The use of trolley eliminates the need of a truck to reach the battery rack in order to extrude the battery on it and take a fully charged battery. Thereby, it causes less damages to the battery racks and maintenance becomes more secure.

In conclusion, it should be noted that only a few companies use the help of professionals, who every day face the challenges of building and equipping of battery rooms. Such persons or companies are not only able to prepare a professional projects of proper distribution of batteries and chargers, but also to plan the process of replacing the batteries, offering the use of equipment that facilitate and accelerate the work. It should also be noted that many of such companies nowadays offer the realization of charging rooms using the system “design and build”, where the customer receives the project, its implementation, as well as all necessary permits and approvals without the involvement of customer’s employees, who can take care of tasks related to the company’s core activities.

Those who are interested in the topic or who are looking for information about charging room welcome to contact the company EnergyOn Sp. o.o., which will offer you a comprehensive offer in consulting, design, and equipment of charging rooms, as well as complete after-sales service and maintenance.

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