Differences in Charging Behavior

Charging Lead-acid Batteries

Lead-acid batteries require a charge rate based on their rated amp-hour capacity. Incorrect charge currents can lead to sulfation, a buildup of corrosive material on the inner lead plates, ultimately shortening the battery’s lifespan. A well-maintained lead-acid battery in the material handling sector can last 4-6 years, and up to 6-8 years with proper care. Key maintenance tasks include regular equalizing charges, maintaining water levels, and monitoring healthy charging tendencies.

Unlike lithium-ion batteries, lead-acid batteries do not incorporate advanced communication technologies or internal Battery Monitoring Systems (BMS). Charging a lead-acid battery involves supplying current at the correct rate using the battery’s positive and negative connections. While older technology from the 1950s-60s is dependable for charging lead-acid batteries, newer high-frequency switching chargers offer higher efficiency, healthier charging, and programmable charge curves.

Charging Lithium-ion Batteries

Lithium-ion batteries also benefit from a charge rate based on their amp-hour capacity but are less sensitive to proper charging tendencies, allowing for faster charging. A well-maintained lithium-ion battery in the material handling industry can last 10-20 years. Unlike lead-acid batteries, lithium-ion batteries do not suffer from sulfation and do not require equalizing charges or water maintenance.

Despite claims of being maintenance-free, lithium-ion batteries do require some maintenance, mainly involving programming adjustments to the charger and BMS, such as updates and troubleshooting. Both battery chemistries necessitate maintenance to varying degrees.

Setting up a charger

Lead-Acid Charger Set-up

Setting up a lead-acid charger involves considering battery specifics, including the correct voltage, output current, and standard connector type. Advanced operations may use a Battery Identification Device (BID) on the charger for automatic programming and performance monitoring across different lead-acid batteries.

Lithium-Ion Charger Set-up

Setting up a lithium-ion charger is determined by the battery manufacturer’s design, with no standardization in the material handling industry for chargers, DC connectors, auxiliary connection pinouts, or BMS protocol signals. This requires direct collaboration with the battery manufacturer to develop a charger that communicates with their specific battery.

Safety

Lead-acid chargers and batteries have a long-established safety record with features like overcharge protection and voltage regulation. In contrast, lithium-ion chargers and batteries, due to their higher energy density and charging rates, require more stringent safety protocols, which are expected to become even more rigorous over time.

Cost

The upfront cost of a lithium-ion battery charger is higher than that of a lead-acid charger. Lithium-ion batteries require high-frequency chargers capable of CAN communication with multiple auxiliary inputs, while lead-acid batteries can be charged with older or simpler technology without auxiliary connections. Lead-acid chargers are typically more affordable and more versatile across different applications, whereas used lithium-ion chargers require accurate reprogramming and rewiring.

Is lithium the future?

Lithium-ion batteries are widely regarded as the future front-runner in battery chemistry, gaining popularity as technology evolves. However, challenges remain for the mass adoption of lithium-ion batteries. Lead-acid batteries are 97% recyclable, making them the most recycled consumer product in the United States, according to Battery Council International. In contrast, lithium-ion batteries are less recyclable, posing future challenges for recycling, safe discharging, and disposal.

Lithium technology is continually evolving, leading to more efficient chargers, batteries, and recycling solutions. This evolution results in lower energy consumption for charging and greater utility from fully charged batteries. While lithium-ion batteries are a hot topic, lead-acid batteries maintain a stronghold in the material handling battery market.

Conclusion

Choosing between lithium-ion and lead-acid batteries is crucial for operational efficiency, runtime, and reliability. While lead-acid chargers have been the industry standard for years, lithium-ion technology offers new possibilities. Evaluating user needs, requirements, and goals is essential to determine the appropriate charger and battery combination.

Whether you’re seeking lithium-ion or lead-acid charging solutions, our GREEN Series chargers are fully customizable to meet your needs, supporting a variety of vehicles, including both light- and heavy-duty applications.