Ensuring the right battery cell chemistry for best performance of mobile industrial robots

The demand for battery-powered products has increased exponentially during our lifetime through the rise of consumer electronics and advances in battery technologies during the 1990’s enabling broader application adoption. The industrial warehouse sector in-particular has seen an significant uptake in battery-powered devices accounting for a large portion of warehouse operations. At Alexander Battery Technologies, we have seen the effect widespread commercial custom battery pack adoption, through the diverse range of commercial battery projects we have been involved in.

With more processes relying on battery-powered vehicles and devices which have wide-ranging jobs to do in varied environments, it is inevitable that the design and development of the batteries that power these products has also changed. There are now more considerations than ever when making design decisions during battery pack design, one of the critical development decisions is which cell chemistry is best suited to the application of the battery pack. The knock-on effect is that more OEMs are choosing custom lithium-ion battery pack designs to enhance the performance of their products, because off-the-shelf solutions often don’t meet the specific requirements of their application.

Mobile robotics is a relatively new technology that is in increased use across various industrial sectors and as organisations become more reliant on robots performing crucial roles, getting them to perform to an optimum level has never been more important.

Popular devices include automated guided vehicles (AGVs) used in materials handling and other applications; automated mobile robots (AMRs) for last-mile deliveries: and frame climbers in automated warehouses.

As more processes become automated, robotic devices increasingly rely on portable battery power systems that deliver continuous output, without unexpected shutdowns due to faults, running out of charge, or premature failure caused by a fault or breakdown.

As workplace robotics continues it’s rapid evolution, battery pack technology is advancing just as quickly to meet new demands. Selecting the right battery chemistry is now essential for maintaining reliable performance.

Lithium-based batteries are the most common choice for new industrial batteries today, because of their high energy density and capacity, giving much longer run-time between charges than any other battery chemistry. With so many types of lithium chemistries used in battery cells, it is important to consider and specify the correct cell type, pack design, and quality for different environments.

With so many lithium chemistries and supporting components like battery charge controller ICs available that support lithium battery packs, robot OEMs often face a complex set of trade-offs. The ideal solution depends on the unique requirements of each application.

A reliable custom battery manufacturer, like Alexander Battery Technologies, will work in collaboration with OEMs to provide expert guidance about these and every other performance attribute of each lithium chemistry, and to advise on the best choice for the OEM’s specific mobile robot application.

Sometimes, this means looking outside of the latest in cell chemistry and battery technology.

For example, when it comes to mobile robotics which are required to perform in extreme temperature ranges, we often turn to one of the older chemistry technologies – lithium titanate (LTO).

Mobile robots that operate in a cold environment, such as a refrigerated warehouse, need to take account of the battery temperature: a lithium cell cannot normally be charged when it is colder than 0°C. This might require the use of active in-pack heating technology to raise cell temperature above 0°C in preparation for charging. In many applications, active heating is a better solution than depositing the pack in a space at room temperature and waiting for it to draw heat from the ambient air.

Strengths and benefits of Lithium Titanate (LTO) batteries

LTO batteries offer some distinct advantages over traditional lithium-ion batteries, particularly those using lithium cobalt oxide (LCO), lithium manganese oxide (LMO), or lithium iron phosphate (LFP) chemistries. The primary strengths and benefits of LTO batteries stem from their unique electrochemical properties, which provide superior performance in several critical areas.

Enhanced safety and stability

One of the most notable strengths of LTO batteries is their exceptional safety profile. Unlike other lithium chemistries, LTO batteries exhibit a minimal risk of thermal runaway, a condition that can lead to overheating and potential combustion. This safety advantage arises from the stable LTO anode, which operates at a higher voltage (around 1.55V versus 0.5V for graphite anodes). This higher voltage reduces the risk of lithium plating and dendrite formation, which are common causes of short circuits and battery fires in traditional lithium-ion batteries.

Long cycle life

LTO batteries are renowned for their cycle life. They can endure between 7,000 to 10,000 charge-discharge cycles or more, significantly surpassing the cycle life of other lithium chemistries. This longevity is due to the minimal volume change in the LTO anode during cycling, reducing mechanical stress and degradation over time. Consequently, LTO batteries offer lower total cost of ownership, especially in applications demanding frequent cycling.

Rapid charging capability

The fast-charging capability of LTO batteries is another key benefit. These batteries can be charged at rates up to 10C, allowing for full recharges in as little as 6 to 10 minutes. This rapid charging is facilitated by the high surface area and excellent conductivity of the LTO anode, which enhances ion transport and reduces resistance. This feature is particularly advantageous in applications where downtime for charging must be minimised.

Wide temperature range performance

LTO batteries are highly tolerant of extreme temperatures, operating effectively from -30°C up to 55°C. This makes them ideal for harsh environments where other lithium batteries may lose capacity or fail. Their stable electrochemical behaviour under these conditions ensures consistent performance and reliability.

Industrial automation and environments

In industrial settings, mobile robots are used for tasks such as material handling, inventory management, and assembly line support. The long cycle life of LTO batteries ensures these robots can operate continuously over extended periods, reducing the need for frequent battery replacements and maintenance downtime. Additionally, the rapid charging capability allows robots to quickly recharge during short breaks, maximising operational uptime.

Mobile robots in warehouses and logistics centres often operate in shifts and require batteries that can be quickly recharged between operations. LTO batteries’ fast-charging ability ensures robots spend minimal time docked and more time performing tasks such as picking, packing, and transporting goods. The wide temperature tolerance of LTO batteries also allows these robots to function effectively in cold storage environments.

AGVs (autonomous guided vehicles), commonly used in manufacturing and warehouse automation, rely on robust and reliable power sources to navigate complex environments and transport heavy loads. LTO batteries’ long cycle life and ability to withstand high discharge rates without significant capacity loss make them ideal for AGVs. The fast charging capability ensures that AGVs remain operational with minimal downtime, enhancing overall productivity.

In summary

Lithium Titanate (LTO) batteries offer numerous advantages over other lithium chemistries, including superior safety, extended cycle life, rapid charging, and reliable performance across a wide temperature range.

These strengths make LTO batteries an excellent choice for powering mobile robots in industrial and business environments. Their use in industrial automation, warehouse logistics, service robots, and AGVs highlights the practical benefits of LTO batteries in enhancing efficiency, safety, and reliability in various demanding applications.

The guidance above shows how careful attention to cell and battery specification, design and production, and the choice of a dependable battery pack manufacturer, can ensure reliable and predictable performance for the life of the robot.