Battery technology

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Battery unit and DC / AC converter unit

Ensuring the power supply is an essential part of mobile workstation solutions. The supply units for the trolley solutions are selected depending on the consumers, especially their supply voltages (AC or DC) and their power consumption (VA).

The supply units of the trolley solutions are dimensioned depending on the power requirements of the consumers and the grid-independent working hours. The question arises very quickly:

Which battery technology should be used?

Below is some basic knowledge and a direct comparison between AGM technology and LiFePo4 battery. We offer both variants.

The classic. The AGM-VRLA DEEP CYCLE battery. The completely sealed lead-acid batteries are designed with absolutely maintenance-free AGM-VRLA technology for a wide variety of applications.

The batteries are manufactured using the latest technology and individually tested. Thanks to a special manufacturing process, the battery is extremely resilient and durable. This results in the high cycle stability. The batteries meet the highest standards and are without a doubt among the most robust and reliable, maintenance-free AGM DEEP CYCLE batteries on the market.

Features ZL Deep Cycle

  • high cycle stability
  • maintenance free
  • locked
  • leakproof
  • long service life, very low self-discharge
  • Safety valve against overpressure (VRLA technology)

The difference:

The positive electrode consists of (LiFePO4) lithium iron sulfate instead of conventional (LiCoO2) lithium cobalt oxide. The negative electrode consists of graphite (hard carbon) with embedded lithium. Such an accumulator has a lower energy density than the conventional LIFO, but does NOT tend to "thermal runaway" - even in the event of mechanical damage.

The difference to conventional lithium-ion cells with lithium cobalt (III) oxide (LiCoO2) becomes clear in the charging or discharging process of the LiFePo battery. No oxygen is released in the chemical reaction. Oxygen, together with lithium cobalt oxide cathodes, can lead to a thermal "accident" in lithium-ion batteries, which, under unfavorable conditions, leads to the cell catching fire on its own.

Due to the solid electrolyte and cell chemistry, LiFePO4 cells are considered intrinsically safe, i.e. H. Thermal runaway and membrane melting, as with lithium-ion batteries, is ruled out.

Below you will find a list of advantages and a comparison between lead gel and LiFePo4 technology:

  • You only need approx. 50% of the lead capacity if you want to switch to LiFePo4, which results in over 50% weight and space savings.
  • A 4 to 5 times higher number of charging cycles results in a significantly longer service life.
  • A full charge is not absolutely necessary with LFP.
  • Very high charging efficiency, almost 100% of the energy fed in can also be withdrawn again.
  • Even 50Ah LFP can supply 1000W inverters with almost any state of charge.
  • High charging and discharging currents possible over the entire state of charge.
  • A battery management system (BMS) is mandatory and already integrated
  • Flexible end-of-charge voltage lead chargers can also continue to be used
  • Unlike LI-ION batteries, lithium batteries are intrinsically safe - there is no risk of fire

At FORSIS, we see a trend that the future will go in the direction of LiFePo technology. The advantages can be seen clearly above.

Technology lead gel

  • Capacity 40Ah, 65Ah, 85Ah or 120Ah
  • Voltage 12V / battery
  • Number of rechargeable batteries 2x pieces always connected in series
  • Charging cycles approx. 500-600 times up to 70% full charge
  • Charging current 10A or 15A max.
  • max.discharge Depending on the total discharge protection approx. 70%
  • Design completely closed housing block form with screw terminals
  • Weight depending on the battery between 28kg and 70kg
  • Dimensions identical
  • DC / AC converter 350W, 600W or 1200 W.

Technology LiFePo

  • Capacity 50Ah / 80 Ah
  • Voltage 24V / battery
  • Number of batteries 1 piece
  • Charging cycles approx. 4000 to 95% full charge
  • Charging current depending on the charger max. 1C
  • max.discharge Depending on the total discharge protection approx. 98%
  • Design completely closed housing block form with screw terminals
  • Weight depending on the battery approx. 13 kg
  • Dimensions identical
  • DC / AC converter 350W, 600W or 1200 W

Using a specific example, we want to work out the dimensioning of a battery supply for a mobile workstation together. We assume that the customer wants to configure a large and flexible system and therefore has a large number of end devices

The following printer components should be used on the mobile workstation: FORSIS PANEL PC PROFI S 2150 MT with scanner and various printers: e.g. 2x ZEBRA ZM400, TSC TTP2410MT, HP Laserjet P3015

1. Determination of supply and consumption

Based on the manufacturer's technical documentation (data sheet, etc.), the first task is to determine the supply voltage and power consumption of the devices. To design the battery technology, we have to consider the following two scenarios: start-up and continuous operation

Supply voltage Information on consumption in terms of current consumption or power

A distinction must be made between print mode or start-up and standby

ZEBRA ZM400 - supply voltage 230V AC / current consumption 5A at 230V AC approx. 1150W n.a.

TSC TTP2410MT - supply voltage 230V AC / power consumption approx. 220 W, no information on current consumption

HP Laserjet P3015 - supply voltage 230V AC / worst case power consumption 750 W, standby operation 10W

PROFI PANEL PC - supply voltage 24V DC / approx. 40W in operation

Scanner - supply voltage 5V DC / power consumption approx. 5W via USB interface of the PANEL PC

Note: The data sheets and manuals often provide relatively nimble information on the maximum values ​​of the devices. An upward tolerance should therefore always be taken into account.

1.1. The start-up of all components at switch-on time.

Here all systems start up and start up at the same time. In particular, the power consumption of the printer must be carefully observed here, and the behavior is similar during printing

The customer now tells us, for example, that the TSC printer is being used and that the following combinations are possible, plus all other consumers such as PC, etc.

Example: Workplace goods receipt:

2x TSC 2x 220 W = 440W

PC technology 40W

Total 480W

Example workstation goods issue:

2x TSC 440W

1x HP 750W

PC technology 40W

Total 1230W

The selection of the DC / AC converter is derived from this. The important thing is that there is room for improvement. The peak at the moment of switch-on must be intercepted by the DC / AC converter. The exact power consumption of the TSC printer is not definitely clear, the 1200W converter appears to be at its limits. To get security, the 1800 W would be an alternative.

2. Workstation hours of operation

It's more about how long my battery will last. As a basis, a mix ratio between usage time and standby time of the consumers is to be found.

The maximum power has already been calculated. The question of the average power consumption, i.e. normal operation, is therefore very important.

In normal operation we assume that the workstations have about 30% power consumption during operation. Please check the data sheet for this.
CAUTION: Does not correspond to the specifications for standby mode.
In normal operation, the total power consumption is, for example, 1.230W * 30% = 369W.

To put it simply, the power that is taken from the DC / AC converter must also be supplied.
AC side: Current consumption: 369VA / 30V = approx. 1.6 A. That means that this 369VA must also be supplied on the 24V DC side.
DC side: Power supply: 369 W / 24V = approx. 15 A

Thus the current draw is approx. 15A from the battery. The power loss of the DC / AC converter is not taken into account in this case.

If you now have a utilization ratio of, for example, 50% in one shift (8 working hours). Need 15A per hour for four hours. So 60Ah.

 

 

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Latest technology - individually tested

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The batteries are manufactured using the latest technology and individually tested. Thanks to a special manufacturing process, the AGM battery is extremely resilient and durable. This results in the high cycle stability. Without a doubt, they are among the most robust and reliable, maintenance-free AGM DEEP CYCLE batteries on the market

Features of the ZL Deep Cycle.

  • high cycle stability * see diagram
  • maintenance free
  • locked
  • leakproof
  • long service life, very low self-discharge
  • Safety valve against overpressure (VRLA technology)

Comparison of lead gel battery versus LiFePo

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The LiFePo4 battery technology is also increasingly in demand. Below you will find a list of advantages and a comparison:

  • You only need approx. 50% of the lead capacity if you want to switch to LiFePo4, which results in over 50% weight and space savings.
  • A 4 to 5 times higher number of charging cycles results in a significantly longer service life.
  • A full charge is not absolutely necessary with LFP.
  • Very high charging efficiency, almost 100% of the energy fed in can also be withdrawn again.
  • Even 50Ah LFP can supply 1000W inverters with almost any state of charge.
  • High charging and discharging currents possible over the entire state of charge.
  • A battery management system (BMS) is mandatory and already integrated.
  • Flexible charging relaxation - lead chargers can also continue to be used.
  • Unlike LI-ION batteries, lithium batteries are intrinsically safe - there is no risk of fire here.
Stephan Brenner Vertrieb

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