{"id":9003,"date":"2026-11-05T10:52:19","date_gmt":"2026-11-05T10:52:19","guid":{"rendered":"https:\/\/holobattery.com\/applications\/agv-mobile-robot-batteries\/"},"modified":"2026-11-05T10:52:19","modified_gmt":"2026-11-05T10:52:19","slug":"agv-mobile-robot-batteries","status":"publish","type":"page","link":"https:\/\/holobattery.com\/applications\/agv-mobile-robot-batteries\/","title":{"rendered":"AGV &#038; Mobile Robot Batteries"},"content":{"rendered":"<style id=\"hb-applications-css\">.page-header{display:none!important}main.site-main.page,main.site-main.page .page-content{max-width:none!important;width:100%!important;margin:0!important;padding:0!important}.hb-page{--ink:#0B141E;--body:#475569;--mut:#64748B;--line:#E2E8F0;--tint:#F8FAFC;--green:#23A455;--green-ink:#19763D;--green-wash:#ECFDF5;--dark:#0B141E;--on-dark:#CBD5E1;font-family:'Inter',-apple-system,BlinkMacSystemFont,\"Segoe 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a{font-weight:600}.hb-page .hb-quote{background:var(--dark);color:var(--on-dark);padding:64px 0}.hb-page .hb-quote h2{color:#fff}.hb-page .hb-quote .hb-sub{color:var(--on-dark);max-width:none}.hb-page .hb-sendlist{margin-top:32px;display:grid;grid-template-columns:repeat(2,1fr);gap:2px 40px;list-style:none;padding:0;font-size:16px}.hb-page .hb-sendlist li{padding:10px 0;border-bottom:1px solid rgba(255,255,255,.12);color:var(--on-dark)}.hb-page .hb-sendlist li::before{content:\"\u2713\";color:var(--green);font-weight:700;margin-right:10px}@media(max-width:900px){.hb-page .hb-hero-grid,.hb-page .hb-two,.hb-page .hb-case,.hb-page .hb-reading{grid-template-columns:1fr}.hb-page .hb-hero{padding-top:32px}.hb-page .hb-sec{padding:40px 0}.hb-page .hb-kpis{grid-template-columns:repeat(2,1fr)}.hb-page .hb-cover>div,.hb-page .hb-fail>div{grid-template-columns:1fr;gap:8px}.hb-page .hb-tiers,.hb-page .hb-sendlist{grid-template-columns:1fr}.hb-page .hb-apps{grid-template-columns:repeat(2,1fr)}.hb-page .hb-case{padding:22px}}@media(max-width:600px){.hb-page h1{font-size:30px;max-width:none}.hb-page .hb-sec-h{font-size:26px}.hb-wrap{padding-left:20px;padding-right:20px}.hb-page .hb-lead{font-size:16px}.hb-page .hb-btn{padding:12px 18px;font-size:14px}.hb-page .hb-apps{grid-template-columns:1fr}.hb-page .hb-mosaic.four{grid-template-columns:repeat(2,1fr)}.hb-page table.hb-spec{min-width:600px}}@media(prefers-reduced-motion:reduce){.hb-page *{transition:none!important}}<\/style>\n<div class=\"hb-page\"><header class=\"hb-hero on-dark\"><div class=\"hb-wrap\"><div class=\"hb-hero-grid\"><div><h1>Custom Battery Packs for AGVs and Mobile Robots<\/h1><p class=\"hb-lead\"><strong>24V and 48V LiFePO4 and NMC packs<\/strong> for AGVs, AMRs and legged robots. Most robot batteries do not die of bad cells; they die of integration: heat trapped in the middle of the pack, resistance in the interconnects, charging in the cold and discharge limits set too deep. We design those out.<\/p><div class=\"hb-hero-cta\"><a class=\"hb-btn hb-btn-primary\" href=\"https:\/\/holobattery.com\/contact\/\">Send your robot&#8217;s current profile<\/a><\/div><nav class=\"hb-toc\" aria-label=\"On this page\"><a href=\"#builds\">Reference builds<\/a><a href=\"#sizing\">Sizing<\/a><a href=\"#failures\">Why AGV packs fail<\/a><a href=\"#peaks\">Peak loads<\/a><a href=\"#bms\">BMS<\/a><a href=\"#faq\">FAQ<\/a><\/nav><\/div><div class=\"hb-mosaic\"><a href=\"https:\/\/holobattery.com\/product\/custom-48v-50ah-lifepo4-agv-battery\/\"><img fetchpriority=\"high\" decoding=\"async\" src=\"https:\/\/holobattery.com\/wp-content\/uploads\/2024\/10\/custom-48v-50ah-agv-battery.png\" alt=\"51.2V 50Ah AGV custom battery pack\" width=\"600\" height=\"600\" fetchpriority=\"high\"><span>51.2V 50Ah AGV<\/span><\/a><a href=\"https:\/\/holobattery.com\/product\/custom-24v-90ah-lithium-agv-battery\/\"><img loading=\"lazy\" decoding=\"async\" src=\"https:\/\/holobattery.com\/wp-content\/uploads\/2025\/08\/25.2V90Ah.png\" alt=\"24V 90Ah AGV custom battery pack\" width=\"600\" height=\"600\" loading=\"lazy\"><span>24V 90Ah AGV<\/span><\/a><a href=\"https:\/\/holobattery.com\/product\/custom-48v-315ah-electric-forklift-battery\/\"><img loading=\"lazy\" decoding=\"async\" src=\"https:\/\/holobattery.com\/wp-content\/uploads\/2024\/10\/custom-48V-315Ah-forklift-lithium-battery.png\" alt=\"51.2V 315Ah custom battery pack\" width=\"600\" height=\"600\" loading=\"lazy\"><span>51.2V 315Ah<\/span><\/a><a href=\"https:\/\/holobattery.com\/product\/custom-48v-100ah-waterproof-lifepo4-battery\/\"><img loading=\"lazy\" decoding=\"async\" src=\"https:\/\/holobattery.com\/wp-content\/uploads\/2026\/05\/custom-48v-100ah-waterproof-battery-for-UGVs.png\" alt=\"48V 100Ah UGV custom battery pack\" width=\"600\" height=\"600\" loading=\"lazy\"><span>48V 100Ah UGV<\/span><\/a><\/div><\/div><\/div><\/header><nav class=\"hb-section-nav\" aria-label=\"Battery applications\"><div class=\"hb-wrap\"><a href=\"https:\/\/holobattery.com\/applications\/\">All applications<\/a><a href=\"https:\/\/holobattery.com\/applications\/marine-battery-packs\/\">Marine<\/a><a href=\"https:\/\/holobattery.com\/applications\/agv-mobile-robot-batteries\/\" aria-current=\"page\">AGV &amp; Robots<\/a><a href=\"https:\/\/holobattery.com\/applications\/forklift-batteries\/\">Forklifts<\/a><a href=\"https:\/\/holobattery.com\/applications\/golf-cart-lsv-batteries\/\">Golf Carts &amp; LSVs<\/a><a href=\"https:\/\/holobattery.com\/applications\/energy-storage-batteries\/\">Energy Storage<\/a><a href=\"https:\/\/holobattery.com\/applications\/drone-uav-batteries\/\">Drones &amp; UAVs<\/a><a href=\"https:\/\/holobattery.com\/applications\/cold-climate-commercial-vehicle-batteries\/\">Cold Climate &amp; Trucks<\/a><\/div><\/nav><section class=\"hb-sec\"><div class=\"hb-wrap\"><div class=\"hb-kpis\"><div><b>4,000+<\/b><span>LFP cycles targeted with conservative voltage limits<\/span><\/div><div><b>&lt;3\u00b0C<\/b><span>Cell-to-cell temperature spread we design for<\/span><\/div><div><b>15\u00b0C<\/b><span>Minimum cell temperature before charging is allowed<\/span><\/div><div><b>CAN \/ RS485<\/b><span>Standard BMS telemetry to the fleet controller<\/span><\/div><\/div><\/div><\/section><section class=\"hb-sec tint\" id=\"builds\"><div class=\"hb-wrap\"><h2 class=\"hb-sec-h\">Robot platforms we build for<\/h2><p class=\"hb-sub\">Reference packs are starting points. Envelope, connector, BMS protocol and current limits are normally adapted to your chassis and drive controller.<\/p><div class=\"hb-tablewrap\" tabindex=\"0\" role=\"region\" aria-label=\"Robot applications and reference packs\"><table class=\"hb-spec\"><thead><tr><th>Platform<\/th><th>Typical voltage<\/th><th>What drives the design<\/th><th>Reference packs<\/th><\/tr><\/thead><tbody><tr><td>Warehouse AGVs and AMRs<\/td><td>24V \u2013 48V<\/td><td>Opportunity charging between tasks, lift-motor peaks, telemetry to the fleet manager<\/td><td><a href=\"https:\/\/holobattery.com\/product\/custom-48v-50ah-lifepo4-agv-battery\/\">51.2V 50Ah AGV (1C, CAN\/RS485)<\/a><br><a href=\"https:\/\/holobattery.com\/product\/custom-24v-90ah-lithium-agv-battery\/\">24V 90Ah AGV<\/a><\/td><\/tr><tr><td>Heavy-load AGVs, tuggers and stackers<\/td><td>48V<\/td><td>Long shifts, high continuous current, fit in an existing battery bay<\/td><td><a href=\"https:\/\/holobattery.com\/product\/custom-48v-315ah-electric-forklift-battery\/\">51.2V 315Ah<\/a><\/td><\/tr><tr><td>Outdoor UGVs and inspection robots<\/td><td>48V<\/td><td>Sealing, vibration, wide temperature range<\/td><td><a href=\"https:\/\/holobattery.com\/product\/custom-48v-100ah-waterproof-lifepo4-battery\/\">48V 100Ah waterproof<\/a><\/td><\/tr><tr><td>Quadruped robots<\/td><td>Project-specific, often 48V<\/td><td>Pulse capability and safety outdoors; LFP usually preferred<\/td><td>Custom design<\/td><\/tr><tr><td>Humanoid robots<\/td><td>Project-specific<\/td><td>Mass and volume budget; NMC 21700 usually preferred, with strong thermal control<\/td><td>Custom design<\/td><\/tr><\/tbody><\/table><\/div><\/div><\/section><section class=\"hb-sec\" id=\"sizing\"><div class=\"hb-wrap\"><h2 class=\"hb-sec-h\">Sizing an AGV pack for opportunity charging<\/h2><div class=\"hb-prose\"><p>An AGV battery does not need to last a full shift if the robot can charge between tasks. Sizing for the longest gap between charging opportunities, instead of the whole shift, often halves pack size and cost. What it cannot shrink is the peak current: lift motors and acceleration set the minimum power capability regardless of energy.<\/p><\/div><div class=\"hb-calc\"><div class=\"hd\">Worked example: 48V warehouse AGV (illustrative numbers)<\/div><ol><li>Average power over a working period, logged from the robot: <code>500 W<\/code><\/li><li>Longest gap between charging opportunities: <code>2 h<\/code> \u2192 energy per gap <code>1.0 kWh<\/code><\/li><li>Usable window: 10% SOC buffer at the bottom and 3.0V\/cell cutoff, plus 20% ageing margin \u2192 rated <code>1.0 \u00f7 (0.9 \u00d7 0.8) \u2248 1.4 kWh<\/code><\/li><li>Peak power, lift motor plus drive: <code>4.5 kW<\/code> \u2192 <code>4,500 \u00f7 51.2 V \u2248 88 A<\/code><\/li><li>Charge acceptance at a 15-minute dock stop at 0.5C on 50Ah: <code>25 A \u00d7 51.2 V \u00d7 0.25 h \u2248 0.32 kWh<\/code><\/li><\/ol><div class=\"res\">Result: a <b>51.2V 50Ah<\/b> pack (2.56 kWh) covers the energy with margin; the deciding check is whether it delivers <b>~90A peaks<\/b> without the voltage dropping below the controller&#8217;s undervoltage limit. Without opportunity charging the same robot would need roughly <b>100\u2013120Ah<\/b> for an 8-hour shift.<\/div><\/div><\/div><\/section><section class=\"hb-sec tint\" id=\"failures\"><div class=\"hb-wrap\"><h2 class=\"hb-sec-h\">Five integration errors that halve AGV battery life<\/h2><p class=\"hb-sub\">Cell quality is rarely the root cause. These five integration mistakes can cut rated cycle life by 50 to 70 percent. Full analysis: <a href=\"https:\/\/holobattery.com\/why-agv-batteries-fail-early\/\">Why AGV Batteries Fail Early<\/a>.<\/p><div class=\"hb-tablewrap\" tabindex=\"0\" role=\"region\" aria-label=\"AGV battery failure modes\"><table class=\"hb-spec\"><thead><tr><th>Failure mode<\/th><th>What happens<\/th><th>Typical integration<\/th><th>How we design it<\/th><\/tr><\/thead><tbody><tr><td>Thermal gradient<\/td><td>Centre cells run 5\u20138\u00b0C hotter and age about 1.5\u00d7 faster; the BMS cuts off while healthy cells still hold charge<\/td><td>&gt; 8\u00b0C spread<\/td><td>Airflow channels and thermal pads to the chassis, &lt; 3\u00b0C spread<\/td><\/tr><tr><td>Interconnect resistance<\/td><td>Under-torqued busbars add 80\u2013150 mV of sag; false low-voltage shutdowns with 20\u201330% charge left<\/td><td>Hand-tightened<\/td><td>Torque-verified busbars (5 Nm), cables sized for peak current<\/td><\/tr><tr><td>Cold charging<\/td><td>Charging LFP below 10\u00b0C plates lithium on the anode and permanently loses capacity<\/td><td>Charge at any temperature<\/td><td>Heaters and BMS charge block until cells reach 15\u00b0C<\/td><\/tr><tr><td>Deep discharge<\/td><td>Cutoffs below 2.8V\/cell grow internal resistance and can halve cycle life<\/td><td>2.5V\/cell, 100% DoD<\/td><td>3.0V\/cell cutoff, 10% SOC buffer<\/td><\/tr><tr><td>Vibration<\/td><td>Floor joints and uneven surfaces fatigue cell tabs; erratic voltage readings<\/td><td>Rigid mounting<\/td><td>Damped tray, foam compression, flexible internal busbars<\/td><\/tr><\/tbody><\/table><\/div><\/div><\/section><section class=\"hb-sec\" id=\"peaks\"><div class=\"hb-wrap\"><h2 class=\"hb-sec-h\">Designing for peak loads, not average loads<\/h2><div class=\"hb-prose\"><p>Robots reset when bus voltage drops below the controller&#8217;s undervoltage lockout during a burst. The cause is DC resistance: at 200A, a pack with 10 m\u03a9 of total loop resistance drops 2V and turns 400W into heat inside the enclosure. On a 24V robot with an 18V logic threshold, a cold start plus acceleration is enough to reboot it.<\/p><p>For systems above 100A peak we target total pack resistance below 2 m\u03a9 at beginning of life, because cell resistance rises about 30% at 0\u00b0C and about 40% by end of life. That target drives the build: high-power cells where the duty cycle needs them, oxygen-free copper busbars instead of nickel strip, ultrasonic welds instead of spot welds, and parallel strings that share the current. Details: <a href=\"https:\/\/holobattery.com\/high-discharge-battery-design-for-mobile-robots\/\">High-Discharge Battery Design for Mobile Robots<\/a>.<\/p><\/div><div class=\"hb-tablewrap\" tabindex=\"0\" role=\"region\" aria-label=\"Peak to average power ratio for legged robots\"><table class=\"hb-spec\"><thead><tr><th>Robot action<\/th><th>Peak power<\/th><th>Average power<\/th><th>Peak-to-average ratio<\/th><\/tr><\/thead><tbody><tr><td>Humanoid: walk to sprint<\/td><td>3.5 kW<\/td><td>800 W<\/td><td>4.4\u00d7<\/td><\/tr><tr><td>Humanoid: fall recovery<\/td><td>4.2 kW<\/td><td>600 W<\/td><td>7.0\u00d7<\/td><\/tr><tr><td>Quadruped: bound gait<\/td><td>2.8 kW<\/td><td>600 W<\/td><td>4.7\u00d7<\/td><\/tr><tr><td>Quadruped: jump landing<\/td><td>6.0 kW+<\/td><td>500 W<\/td><td>12\u00d7+<\/td><\/tr><\/tbody><\/table><\/div><p class=\"hb-note\">Representative figures for legged robots. A pack sized only for average power will collapse during these transients. More: <a href=\"https:\/\/holobattery.com\/battery-solutions-high-transient-loads-quadruped-humanoid-robots\/\">High Transient Load Batteries for Quadruped and Humanoid Robots<\/a>.<\/p><\/div><\/section><section class=\"hb-sec tint\" id=\"bms\"><div class=\"hb-wrap\"><h2 class=\"hb-sec-h\">BMS and integration<\/h2><dl class=\"hb-cover\"><div><dt>Communication<\/dt><dd>CAN and RS485 as standard, so state of charge, temperature and fault flags reach the robot and the fleet manager. Having the interface is not the same as matching your protocol: send the protocol document and we confirm the registers before quoting. See <a href=\"https:\/\/holobattery.com\/battery-communication-protocol-options\/\">battery communication protocol options<\/a>.<\/dd><\/div><div><dt>Fast current sensing<\/dt><dd>Motor stalls last 20\u201350 ms. For high-rate robots the BMS needs to sample fast enough to see them and tell the drive controller to reduce torque before a hard cutoff.<\/dd><\/div><div><dt>Charging contacts<\/dt><dd>Charge current, voltage and the handshake with your docking station agreed up front, including temperature-gated charging for cold stores and freezer aisles.<\/dd><\/div><div><dt>Chemistry choice<\/dt><dd>LiFePO4 for most AGVs and outdoor robots: safety, cycle life and low resistance. NMC for humanoids and mass-critical designs. Trade-offs: <a href=\"https:\/\/holobattery.com\/lithium-ion-and-lithium-iron-phosphate-battery\/\">lithium-ion vs LiFePO4<\/a>.<\/dd><\/div><div><dt>Standards<\/dt><dd>Industrial lithium packs are typically assessed against IEC 62619, with UN38.3 for transport. Which reports cover your exact design is confirmed at quotation.<\/dd><\/div><\/dl><\/div><\/section><section class=\"hb-sec\"><div class=\"hb-wrap\"><h2 class=\"hb-sec-h\">Lead time and order quantity<\/h2><p class=\"hb-sub\">From a locked specification: samples in 12\u201315 working days when cells are in stock, 20\u201325 when cells must be sourced; production in 30\u201335 working days. From the first design conversation: about 4 weeks for a finalised design with no new tooling, 8\u201312 weeks for a typical custom project, 14\u201318 weeks when certification is in scope. How each phase works: <a href=\"https:\/\/holobattery.com\/custom-batteries\/\">custom battery pack development process<\/a> and <a href=\"https:\/\/holobattery.com\/battery-pack-manufacturing\/\">our manufacturing capabilities<\/a>.<\/p><div class=\"hb-tiers\"><div class=\"hb-tier\"><div class=\"bar\"><i><\/i><\/div><b>No MOQ<\/b><span>When no tooling and no custom BMS firmware are needed.<\/span><\/div><div class=\"hb-tier\"><div class=\"bar\"><i><\/i><\/div><b>100+<\/b><span>Once tooling or custom BMS firmware enters the project.<\/span><\/div><div class=\"hb-tier\"><div class=\"bar\"><i><\/i><\/div><b>300\u2013500<\/b><span>For heavily customised packs with certification.<\/span><\/div><\/div><\/div><\/section><section class=\"hb-sec tint\" id=\"faq\"><div class=\"hb-wrap\"><h2 class=\"hb-sec-h\">AGV and robot battery questions<\/h2><div class=\"hb-faq\"><details><summary>Why does my AGV&#8217;s battery percentage drop suddenly during lifts?<\/summary><div class=\"a\">A high current draw through resistive connections causes a voltage dip, and the BMS state-of-charge estimate jumps down with it. Check busbars for oxidation and torque, and check cable sizes against peak current rather than average current.<\/div><\/details><details><summary>LiFePO4 or NMC for a mobile robot?<\/summary><div class=\"a\">LiFePO4 for most AGVs, AMRs and outdoor robots: lower resistance in prismatic and 32700 formats, longer cycle life and safer chemistry. NMC when mass and volume dominate, as in humanoids, accepting tighter thermal management.<\/div><\/details><details><summary>Does an AGV battery need active cooling?<\/summary><div class=\"a\">For multi-shift, high-duty-cycle robots, usually yes. Passive designs cannot remove heat from the middle of a dense pack, and those centre cells age first.<\/div><\/details><details><summary>Can the robot work in cold stores?<\/summary><div class=\"a\">Yes, if the pack heats itself before charging and the BMS refuses charge below a safe cell temperature. For very cold, intermittently charged equipment, sodium-ion is also worth considering; see <a href=\"https:\/\/holobattery.com\/applications\/cold-climate-commercial-vehicle-batteries\/\">cold-climate batteries<\/a>.<\/div><\/details><details><summary>Can you build to our existing battery drawings?<\/summary><div class=\"a\">Yes. Send the drawing, connector and protocol details; we review it and flag anything likely to cause field failures before we quote.<\/div><\/details><\/div><\/div><\/section><section class=\"hb-sec\"><div class=\"hb-wrap\"><h2 class=\"hb-sec-h\">Further reading<\/h2><div class=\"hb-reading\"><a href=\"https:\/\/holobattery.com\/why-agv-batteries-fail-early\/\"><b>Why AGV Batteries Fail Early<\/b><span>The five integration errors, with engineering fixes.<\/span><\/a><a href=\"https:\/\/holobattery.com\/high-discharge-battery-design-for-mobile-robots\/\"><b>High-Discharge Battery Design for Mobile Robots<\/b><span>DCR, interconnects and BMS sampling for burst loads.<\/span><\/a><a href=\"https:\/\/holobattery.com\/battery-solutions-high-transient-loads-quadruped-humanoid-robots\/\"><b>Batteries for Quadruped and Humanoid Robots<\/b><span>Peak-to-average power and chemistry selection.<\/span><\/a><a href=\"https:\/\/holobattery.com\/active-vs-passive-bms-balancing-lfp-and-high-voltage-packs\/\"><b>Active vs Passive BMS Balancing<\/b><span>When balancing strategy matters for LFP packs.<\/span><\/a><\/div><\/div><\/section><section class=\"hb-quote\"><div class=\"hb-wrap\"><h2 class=\"hb-sec-h\">Send your robot&#8217;s battery requirements<\/h2><p class=\"hb-sub\">An engineer replies with questions or a proposed configuration. The more of this list you can share, the faster we can quote:<\/p><ul class=\"hb-sendlist\"><li>Robot type and payload<\/li><li>Nominal voltage and drive controller model<\/li><li>Logged current profile, or average and peak current<\/li><li>Charging method and gap between charges<\/li><li>Battery bay dimensions and weight limit<\/li><li>Operating temperature, including cold stores<\/li><li>Communication protocol<\/li><li>Annual volume and target standards<\/li><\/ul><a class=\"hb-btn hb-btn-primary\" style=\"margin-top:32px\" href=\"https:\/\/holobattery.com\/contact\/\">Send your robot&#8217;s battery requirements<\/a><\/div><\/section><\/div>","protected":false},"excerpt":{"rendered":"<p>Custom 24V\u201348V packs for AGVs, AMRs and legged robots: opportunity-charge sizing, low-resistance builds for peak loads and CAN\/RS485 BMS.<\/p>\n","protected":false},"author":1,"featured_media":0,"parent":9002,"menu_order":2,"comment_status":"closed","ping_status":"closed","template":"","meta":{"footnotes":"","_members_access_role":[],"_members_access_error":""},"class_list":["post-9003","page","type-page","status-publish"],"_links":{"self":[{"href":"https:\/\/holobattery.com\/wp-json\/wp\/v2\/pages\/9003","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/holobattery.com\/wp-json\/wp\/v2\/pages"}],"about":[{"href":"https:\/\/holobattery.com\/wp-json\/wp\/v2\/types\/page"}],"author":[{"embeddable":true,"href":"https:\/\/holobattery.com\/wp-json\/wp\/v2\/users\/1"}],"replies":[{"embeddable":true,"href":"https:\/\/holobattery.com\/wp-json\/wp\/v2\/comments?post=9003"}],"version-history":[{"count":0,"href":"https:\/\/holobattery.com\/wp-json\/wp\/v2\/pages\/9003\/revisions"}],"up":[{"embeddable":true,"href":"https:\/\/holobattery.com\/wp-json\/wp\/v2\/pages\/9002"}],"wp:attachment":[{"href":"https:\/\/holobattery.com\/wp-json\/wp\/v2\/media?parent=9003"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}