25C Li-Polymer System Powers Warehouse AGVs Through 3 Shifts
A logistics operator struggled with AGV downtime from underspecified packs. EPT deployed a 22.2V 6S high-drain system with smart BMS and field-swappable modules.
At a Glance
Project snapshot
- Industry: Industrial equipment — warehouse AGV / AMR fleets
- Challenge: Eliminate mid-shift failures under 25C continuous load
- Solution: 22.2V 6S Li-polymer with smart BMS and modular swap trays
- Outcome: 3-shift uptime, 40% faster charge, 30% less maintenance downtime
- Fleet scale: 200+ robots across two distribution centers
Key outcomes
- Continuous discharge
- 25C
- Charge time reduction
- 40%
- Downtime reduction
- 30%
- Fleet size
- 200+ AGVs
The Challenge
Peak pick-season loads pushed existing packs into thermal throttle, forcing unplanned swaps and bottlenecking throughput. The integrator needed a drop-in electrical upgrade with minimal chassis rework.
- 25C continuous draw during ramp acceleration
- Opportunity charging between missions
- Field replacement in under 90 seconds
Our Approach
EPT specified a 22.2V 6S pouch array with cell-level monitoring and active balancing. Swap trays aligned with the existing mechanical bay; BMS firmware exposed SOC, SOH, and fault codes to the fleet controller.
- Custom XT90 anti-spark interface and CAN telemetry
- Thermal modeling validated for sealed enclosure airflow
- On-site commissioning and operator swap training
Results
Both sites sustained three-shift operation through peak season without battery-related line stoppages. The integrator standardized on EPT packs for new AGV builds nationwide.
- 30% reduction in battery-related maintenance tickets
- Fleet controller integration completed in one sprint
- Adopted as reference design for next-gen AMR platform
FAQ
Frequently asked questions
- Can EPT batteries integrate with fleet management software?
- Yes. We expose SOC, SOH, fault codes, and temperature via CAN, RS485, or custom protocols so your controller can schedule charging and predict maintenance.
Planning a similar project?
Share your constraints and target specs—our engineers will respond within one business day.
