Optimizing Battery Packs for Mobile Industrial Robots in Hazardous Environments
Part 2: Navigating Technical Trade-offs and Enhancing Reliability
Welcome back to the second part of our exploration into optimizing battery packs for mobile industrial robots in hazardous environments. In the first part, we discussed the significance of intrinsic safety and the choice of battery chemistry. Now, we will dive deeper into the technical trade-offs, cycle life, charge time, and other essential features to ensure the reliability and efficiency of your mobile robots.
Balancing Technical Trade-offs
The proliferation of lithium chemistries and components like battery charge controller ICs presents a complex set of trade-offs for robot OEMs. Key parameters to consider include:
- Energy density: Affects the size and weight of the battery pack.
- Maximum peak power output: Determines the pack’s capability to handle high loads.
- Maximum safe operating temperature and thermal runaway susceptibility: Critical for safety in hazardous environments.
- Cycle life: The number of charge/discharge cycles the battery can endure.
- Nominal output voltage: Must match the robot’s requirements.
- Maximum charge rate: Influences how quickly the battery can be recharged.
For instance, a small AGV or AMR carrying light loads will prioritize high energy density to minimize the battery’s size and weight, often leading to the choice of NMC cells that can be suitable up to a certain energy level. Conversely, a large mobile lifting platform that moves heavy loads can afford a bulkier battery, making LFP cells a better option due to their longer cycle life and safer high-temperature operation.
Cycle Life and Charge Time
For many mobile robots, cycle life and charge time are vital. AGVs in smart warehouses might operate continuously, requiring an interchangeable battery pack system to allow for quick swapping of discharged packs with freshly charged ones. This necessitates cells capable of enduring numerous charge cycles and supporting fast charging. A reputable battery pack manufacturer can provide guidance on these attributes and advise on the best chemistry and engineering practices for specific applications.
Features and Approvals
The choice of chemistry is just the beginning. Evaluating a custom battery pack manufacturer involves assessing features and quality, including:
- Thermal management: Effective heat dissipation is crucial for safety and efficiency. Advanced designs may use innovative cell configurations to manage heat, reducing the need for bulky heatsinks.
- Telematics: Real-time data on charge status, temperature, and other parameters can enhance fleet management.
- Regulatory compliance: Understanding the regulatory landscape is essential for global marketability. The battery pack must meet standards and obtain certifications for each target market including regulations for transportation and storage.
Quality and Reliability
Quality in battery pack manufacturing begins with selecting top-tier lithium cells from reputable suppliers. The production process must incorporate stringent quality controls from design through to assembly. Techniques like advanced optical inspection ensure structural integrity, particularly in elements prone to failure, such as welds.
Supporting Intrinsic Safety in Hazardous Environments
At ADOTT Solutions, our expertise extends to designing battery packs for intrinsically safe environments, where safety standards are paramount. We specialize in incorporating advanced technologies, including the latest solid-state battery solutions like Lithium Ceramic Batteries (LCB), which offer the highest safety and energy density.
Our solutions are compliant with international standards like
IEC 60079, 62133, 62619, UL1973, 1642 and directives like ATEX, and we continuously innovate to stay ahead of evolving safety requirements. We understand that standards sometimes lag behind technological advancements, so we ensure our designs not only meet but exceed current safety regulations.
Conclusion
The advancement of digitalized manufacturing practices is driving a surge in mobile robot deployment. Reliable, high-performance battery packs are crucial for maintaining uninterrupted operations. By carefully specifying battery chemistry, design, and production processes, and choosing a dependable manufacturer, operators can ensure their mobile robots perform reliably throughout their operational life.
