Classification of Lithium Battery Cells for Forklifts

Classification of Lithium Battery Cells for Forklifts

Overview

Lithium battery cells are the core components in designing high-quality battery packs for electric forklifts. Understanding the different types—classified by chemistry and form factor—will help you choose the optimal solution for your needs.

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🔋 I. Classification by Chemistry

1. LFP – Lithium Iron Phosphate (LiFePO₄)

Specifications:

• Nominal voltage: ~3.2V/cell

• Energy density: ~90–120 Wh/kg

• Lifespan: 3,000–6,000 cycles

• Operating temp: -20°C to 60°C

• Max discharge rate: 1C–3C

Pros:

• Very safe and chemically stable

• Long lifespan — ideal for continuous forklift operations

• Minimal voltage drop during deep discharge

• Cobalt-free and environmentally friendly

• Affordable (mass production in China)

Cons:

• Heavier than NMC → requires more space

• Poor cold-weather performance without heating

Applications:
Electric forklifts, electric buses, industrial energy storage systems.

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2. NMC – Nickel Manganese Cobalt Oxide (LiNiMnCoO₂)

Specifications:

• Nominal voltage: ~3.7V/cell

• Energy density: 150–220 Wh/kg

• Lifespan: 1,000–2,000 cycles

• Operating temp: 0°C to 45°C

• Max discharge rate: 1C–2C

Pros:

• High energy density, compact and lightweight

• Stable output → suitable for high-speed warehouse forklifts

Cons:

• Can overheat and catch fire if not properly managed

• Shorter lifespan than LFP

• Higher cost due to cobalt

Applications:
Electric vehicles (EV), drones, clean warehouse forklifts, supermarkets.

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🧱 II. Classification by Form Factor

1. Prismatic Cells

• Structure: Aluminum shell, rectangular

• Capacity: 20Ah – 300Ah

• Pros:

  • Easy to install

  • Fewer cells → simpler BMS

  • Good heat dissipation

• Cons:

  • May swell if not secured properly

• Applications: Electric forklifts, energy storage systems

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2. Cylindrical Cells (e.g., 18650, 21700, 32700)

• Structure: Metal casing, cylindrical

• Capacity: 2Ah – 6Ah

• Pros:

  • Mass production → low cost

  • Excellent discharge and cooling

• Cons:

  • Requires many cells → complex BMS

  • Risk of connection failure if not spot-welded properly

• Applications: E-bikes, power tools. Not recommended for industrial forklifts.

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3. Pouch Cells

• Structure: Thin, lightweight, flexible foil pouch

• Pros:

  • Lightest option

  • Highly customizable sizes

• Cons:

  • Fragile and prone to swelling

  • Requires solid external frame

• Applications: Electronics, e-bikes. Rarely used in forklifts.

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✅ III. Recommended Options for Forklifts

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📌 IV. Common LFP Prismatic Cells Used in Forklifts

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📦 V. Notes for Battery Pack Assembly

Before building a battery pack, consider:

• Load and motor specs (e.g. 2.5 tons, AC motor)

• Available battery space (e.g. 900×300×300mm)

• Required operation time (e.g. 8 hours/day)

This data helps calculate:

• Number of cells required

• Suitable cell type

• BMS and discharge design

Conclusion:
Choosing the right lithium cell for electric forklifts is key to ensuring performance, safety, and durability. Need help designing a pack or selecting cells? Leave a message — I’ll support you in detail!