DC Velocity - August 2010

changing equipment and the EBatt battery management software. He recommends a battery-discharge indicator and an interrupt that prevents the truck from operating when the battery is too low, to help spread visits to the changing room out over the course of a day.

Another approach is a system that schedules changes and electronically notifies operators of their “appointments.” “You can schedule them almost like at an airport, queuing them up so the productivity of the warehouse is not adversely impacted,” says Joe LaFergola, manager of business and information solutions for lift-truck maker Raymond Corp. Raymond offers that capability in its i Warehouse fleet management solution.

There are many ways to help drivers get in and out of the room in just a few minutes yet still connect to the right charger and choose the correct battery. Some are low tech, such as marking parking spaces on the floor or color-cod-ing the battery connectors based on the type of truck— one color for reach trucks, another for stock pickers, and so forth. Hal Vanasse, vice president, sales and marketing for Philadelphia Scientific, a manufacturer of battery management systems and equipment, suggests organizing batteries and their associated chargers into “pools.” For example, all pallet jack chargers and batteries would be grouped together.

Technology is playing a big role in matching the truck,
charger, and battery in the most efficient, cost-effective way.
Battery management systems on the market monitor charg-
ing, track each battery’s status, optimize rotation, direct
operators to the correct batteries and chargers, and alert
managers when something is wrong, among other features.
Just one of many possible examples: When drivers enter a
room equipped with Philadelphia Scientific’s iBOS battery
management system, they select the proper “pool” on a
touch screen and are directed to the rack location for the
next available fully charged and cooled battery for that type
of truck. If the driver does not take the specified battery, a
“shouter” alarm sounds over a loudspeaker, telling the driv-
er (and everyone else within earshot) that he’s taken the
wrong one.

Play it safe

There are many opportunities for accidents—including fatal ones—to happen in a battery room, so safety must be top of mind throughout the planning stage. Although this complex subject merits an article of its own, we asked the experts for a few safety tips. What follows are their recommendations:

; Place safety equipment like goggles, gloves, and aprons where operators can easily grab them before they get to the battery handling area. In addition, make sure the path to the eye-wash station is kept clear of obstructions.

; Comply with specific ventilation requirements to prevent the buildup of explosive hydrogen gas emitted by bat-

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