1. 2016 Maintenance Innovation Challenge
Navitas Systems Starlifter Lithium Forklift Battery System
PROBLEM STATEMENT
DLA currently has two thousand electric forklift trucks in various warehouse facilities that incur large associated operating expenses by the long-standing/necessary use of lead acid batteries.
Current lead acid technology suffers from short life, a requirement for up to 3 batteries per forklift truck to maintain constant duty during two-three shift operations, high maintenance costs, and poor cold temperature performance.
Two-three year wearout/replacement costs of Lead acid batteries exceed the cost of the actual forklift trucks over 10 years.
Driver downtime from waiting for battery change-outs and slower lifting as lead acid voltage sags during discharge all adversely affect driver productivity.
BENEFITS
Proposed lithium battery technology will improve operational capability and reduce associated battery costs by up to 30% in the categories articulated below:
TECHNOLOGY SOLUTION
WAY FORWARD
22 kilowatt hour 36 Volt Lithium battery for Class 1 & 2 forklift trucks
Fast charger to enable quick fill-ups during breaks; also enables fully depleted battery to be recharged between shifts in one hour (vs 8 hours to charge/8 hours to cool down for lead acid)—Starlifter never needs to be removed from forklift
Battery fits within designed metal sleeve to bring battery up to weight/size of lead acid battery for providing suitable counter-weight.
Graphical user interface provides driver with information on various battery performance parameters
Instrumented comparison of 6 Starlifter-powered vs 6 Lead Acid-powered Class 2 forklifts at DLA Susquehanna warehouse facility commences November 2016 to assess economic and operational benefits of lithium forklift battery technology
Starlifter Battery
Independent Test Results