Walkie Forklift

How much electricity (in watts) does an electric forklift battery charger actually use.?

I can calculate various chargers’ maximum draw (based on volts times amps) but doesn’t a charger cycle down to a trickle charge after a certain period. I want to know roughly how much a standard battery for a counter balance truck, order picker, and a walkie-rider takes to charge (in watts).

Sophisticated chargers such as what we build here don’t necessarily go down to a trickle charge unless programmed to. But it’s not really necessary, we have customers who charge at and even above battery amp-hr capacity rates all the way to 100%, provided periodic equalization charges are also performed.

As to your question and ignoring losses, the voltage of the battery times the kiloamp-hour capacity of the battery gives you the energy storage capacity in kWhrs. Watts is a rate, which, times time is energy, and you may charge a battery at a very wide range of rates, from trickle on up. If you want fast charging it will take more watts. We make chargers up to 30kW at 500A, which is able to charge a fully-depleted 48V, 1000Ahr battery in about 2hr. Of course, such aggressive rates require that the battery pack have it’s own dedicated monitor, permanently mounted and powered, which communicates to the charger information like state of charge, electrolyte temperature, etc when plugged into the charger.

As far as efficiency, it’s pretty good, at least chemically. Where the losses are is mostly resistive, in the plates and cables according to I^2R. Even taking that into account, it’s still pretty good, though I couldn’t give you a solid number for either case. It also depends on how aggressive your charge rates are to some extent, and what percentage of amp-hrs is spent equalizing, which is mostly wasted (yet necessary for good battery life) power.

I think a reasonable and conservative estimate might be to assume efficiency at maybe 75%, though it could be higher. I’m certain that it is much higher than propane-powered.

Feel free to email me if you’d like more info, here’s our website -

http://www.aerovironment.com/PosiCharge.asp

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As to the charger efficiency, ours is pretty good. I’m the test engineer in that department, our larger units are well over 90% efficient near full power.

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