Core Logic for Selecting Electric Forklift Batteries

The core logic is to match batteries based on four dimensions: operation duration, work intensity, environmental conditions, and budget. For single-shift low-intensity operations, lead-acid batteries are suitable; for multi-shift high-intensity operations or special environments, lithium iron phosphate (LiFePO₄) batteries are preferred.

I. Core Evaluation Dimensions (Clarify Your Needs First)

• Daily Operation Duration: ≤ 6 hours (single shift), 6–10 hours (double shifts), ≥ 10 hours (multiple shifts)
• Work Intensity:
• Intermittent operation (e.g., small warehouses)
• Continuous high-frequency operation (e.g., logistics sorting)
• Heavy-load climbing (e.g., heavy goods handling in workshops)
• Environmental Conditions:
• Normal temperature (0–35℃)
• Low temperature (≤ 0℃, e.g., cold storage)
• Humid/dusty environments (e.g., outdoor freight yards)
• Budget Priority: Priority on initial investment, priority on long-term operating costs

II. Typical Scenarios & Battery Matching Solutions

III. Three-Step Practical Selection Process

1. Determine the battery voltage (match the forklift model)
• Light-duty forklifts (≤ 2 tons): 24V / 36V
• Medium-duty forklifts (2–5 tons): 48V
• Heavy-duty forklifts (> 5 tons): 80V
2. Calculate the required capacity (avoid insufficient endurance)
• Simplified formula: Capacity (Ah) = Forklift operating current (A) × Daily operation duration (h) ÷ Depth of Discharge (DOD) coefficient
• DOD for lead-acid batteries: 50%–60%
• DOD for lithium iron phosphate batteries: 80%–90%
• Example: For a 48V forklift with an operating current of 100A and 8 hours of daily operation, the required lithium battery capacity is 100 × 8 ÷ 0.8 = 1,000 Ah.
3. Lock the battery type based on the scenario (refer to the matching table in Step II)

IV. Key Considerations

1. Prioritize Total Cost of Ownership (TCO): Although lithium batteries have a higher initial price, their 10-year TCO is 40% lower than that of lead-acid batteries, making them more cost-effective for high-frequency use.
2. Match the forklift manufacturer’s requirements: Avoid voltage/interface incompatibility; some forklifts require a dedicated Battery Management System (BMS).
3. Pay extra attention to special needs: For low-temperature environments, select "low-temperature-adapted lithium iron phosphate batteries"; for outdoor operations, confirm the battery’s protection rating (IP65+ is better).