This custom AGV LiFePO4 battery project shows how a battery system can be configured for automated guided vehicles, autonomous mobile robots and warehouse automation equipment.
The engineering review covers vehicle voltage, battery capacity, average operating current, startup current, required runtime, charging-station compatibility, CAN or RS485 communication and installation dimensions.
An AGV or AMR battery must supply the normal drive and control loads while supporting the higher current required during acceleration, lifting, turning and motor startup.
Before selecting the battery, confirm:
The following configuration is an engineering reference for a medium-size 48V warehouse AGV. It is not presented as measured data from the vehicle shown in the photographs.
| Vehicle System Voltage | 48V |
|---|---|
| Nominal Battery Voltage | 51.2V |
| Rated Capacity | 100Ah |
| Nominal Energy | 5120Wh |
| Reference Average Current | 25A planning value; replace with measured vehicle data |
| Discharge Current Limits | 100A continuous, 200A for up to 2 minutes and 600A for 1 second |
| Maximum Continuous Output | Approximately 5120W at 51.2V and 100A |
| Reference Drive Load | Up to approximately 5kW, subject to controller current, startup load and duty-cycle validation |
| Reference Charger | 58.4V 18A CC/CV LiFePO4 charger |
| Calculated Charging Time | Approximately 5.6 hours from empty under ideal conditions |
| Reference Enclosure Dimensions | Approximately 19.88 × 12.32 × 9.25 in for the referenced metal-enclosure configuration |
| Communication Options | CAN or RS485 available when configured for the vehicle and charging-station protocol |
Important: The 25A average current, 5kW drive load and calculated runtime are planning references. Confirm them with the AGV controller specification, current logs and vehicle testing before approving the production battery.
AGV operating time is determined mainly by average current over a complete duty cycle rather than the short peak current used during acceleration or motor startup.
Estimated Runtime = Planning Battery Capacity ÷ Average Operating Current
If 80Ah is used as the planning capacity, equal to 80% of the rated 100Ah capacity, the calculated runtime is:
| Average Operating Current | Calculated Runtime |
|---|---|
| 15A | Approximately 5.3 hours |
| 20A | Approximately 4.0 hours |
| 25A | Approximately 3.2 hours |
| 40A | Approximately 2.0 hours |
These figures are calculation examples rather than measured AGV results. Actual runtime depends on vehicle weight, acceleration, travel speed, route gradient, lifting cycles, idle time, motor efficiency, accessory loads, temperature and battery reserve.
The battery should be selected from the complete vehicle-current profile rather than a single maximum-current value.
The current review should separate:
The reference configuration supports 100A continuously, up to 200A for two minutes and up to 600A for one second. The AGV controller and motor load must remain within these time-dependent limits.
A controller’s phase-current rating is not the same as the current drawn from the battery. Battery-current data should be obtained from the controller specification or measured during representative vehicle operation.
The reference system uses a 58.4V 18A CC/CV charger. At an ideal constant output of 18A, charging a 100Ah battery from empty requires approximately 5.6 hours before allowing for charging losses, battery temperature and current tapering.
For an AGV charging station, confirm:
A fixed 18A charger is suitable for overnight or scheduled charging. Opportunity-charging systems may require a higher charging current, but the cells, BMS, connector, cables and charging station must all be approved for that current.
CAN or RS485 communication can be configured to exchange battery status, charging limits and fault information with the AGV controller or charging station.
The communication specification should define:
CAN and RS485 are not universal plug-and-play protocols. The controller model, charger model, message definition, baud rate and connector pinout must be confirmed before sample production.
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The reference dimensions apply only to the specific metal-enclosure configuration used for preliminary planning. The final AGV battery enclosure must be developed around the actual vehicle compartment and mounting structure.
Mechanical information required before production includes:
A custom steel or engineered enclosure can be developed when a standard battery case does not fit the vehicle compartment, mounting points or connector layout.
The traction-power connector, charging connector and communication connector should be selected separately according to their electrical and mechanical requirements.
Connector ratings must cover continuous current, short-duration current, mating cycles, vibration and the expected operating environment.
The reference values should be replaced with measured project data after the sample battery and AGV have been tested together.
Validation should include:
We support AGV manufacturers, AMR developers, automation integrators and warehouse-equipment suppliers with custom LiFePO4 battery development and production.
OEM and private-label options include:
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AGVs can use 24V, 36V, 48V or other application-specific systems. This reference uses a 51.2V LiFePO4 battery for a 48V vehicle. The battery voltage must match the vehicle controller and charging station.
Capacity is based on measured average operating current, required runtime, charging opportunities, battery reserve, temperature and available installation space.
Record both the maximum current and its duration during acceleration, motor startup, lifting and other high-load operations. Both values must remain within the battery and BMS limits.
Yes, in many applications. The vehicle voltage, controller current, charger, connectors, battery dimensions, counterweight requirements and communication system must be reviewed before conversion.
Selected BMS configurations support CAN or RS485 communication. The protocol, message format, baud rate, controller model and connector pinout must be confirmed before production.
It may be retained if its output voltage, current, charging profile, communication logic, contacts and safety controls are compatible with the approved LiFePO4 battery.
Yes. Enclosure dimensions, mounting points, power connectors, charging contacts, communication connectors and cable outlets can be developed for qualified OEM projects.
Send us the vehicle voltage, required capacity, measured average and startup current, required runtime, battery-compartment dimensions, drive-motor power, controller model, charging-station specification, CAN or RS485 protocol and estimated order quantity.
Our engineering team will review the requirements and recommend a suitable AGV LiFePO4 battery configuration for sample development and vehicle testing.
