From lead-acid to lithium-ion: Battery replacement and performance optimization in industrial forklifts

Automotive and heavy machinery manufacturers, not remaining indifferent to these developments, have accelerated their efforts to reduce carbon emissions significantly over the last decade. Leading companies in the automotive and machinery sectors have developed environmentally friendly technologies to address the harmful effects of carbon monoxide in exhaust gases on humans and the environment. Problems related to battery power, charging times, and lifespan have been overcome, and the prices of necessary materials have significantly decreased. The resulting high profitability after use has led to considerable interest in electric vehicles and machinery from both individual users and corporate companies. Electric forklifts, the subject of this study, initially entered the market with traction batteries due to the high cost and safety concerns of lithium-ion batteries at the time. Although traction batteries have lower safety risks compared to lithium-ion batteries, they are insufficient in terms of economic lifespan. This study examines the theoretical results and costs of transitioning to lithium-ion batteries for the electric forklifts of a company that has been using traction batteries for approximately nine years. Since the wear and power consumption of each electric forklift vary due to different working conditions, data was collected in real time from three electric forklifts operating in various environments. These forklifts performed loading, unloading, and transport tasks under their regular shift conditions. Using this data, a load profile was created, and the current draw rates were determined based on the tasks performed during a shift. The aim was to design the most suitable and cost-effective lithium-ion battery possible based on these findings.