An engineer-to-engineer guide to selecting the right AGV battery architecture, balancing uptime, integration, scalability and cost.

An automated guided vehicle (AGV) that stops for power can bring an entire production process to a standstill. In warehouses and manufacturing environments where vehicles operate across multiple shifts, battery selection is ultimately an uptime decision.

Choosing the right AGV battery means looking beyond voltage and capacity. Duty cycles, charging strategy, available space, battery management system (BMS) integration and long-term maintenance all influence which solution makes the most operational sense.

There are two main approaches:

  • Modular battery packs: Proven, standard battery modules combined to achieve the required voltage and capacity.
  • Custom battery packs: Battery systems engineered around a specific vehicle’s mechanical dimensions and electrical requirements.

For many applications, the most effective approach is modular where possible and custom where necessary.

What is the difference between modular and custom AGV batteries?

A modular AGV battery uses standard battery modules that can be configured to achieve the required system voltage and capacity. Depending on the design, modules may be connected in series or parallel, with the configuration specified and validated by the battery manufacturer.

A custom AGV battery pack is engineered around a particular vehicle. Its dimensions, electrical characteristics, enclosure, BMS and communication interfaces are developed to meet the vehicle’s requirements.

The main difference is flexibility. Modular systems offer a proven starting point, while custom packs provide greater control over the final design.

Neither is automatically better. The right choice depends on how the AGV operates and what its integration requirements demand.

Modular vs custom AGV battery packs: how do they compare?

The following comparison highlights the main considerations for AGV manufacturers and fleet operators.

Consideration Modular AGV Battery Custom AGV Battery Pack
Lead time Typically faster using established designs and components. Requires specification, engineering and prototype development.
Upfront cost Generally lower initial development costs. Potentially higher initial engineering investment.
Tight chassis fit Limited by available module and enclosure dimensions. Designed around the vehicle’s available space and mounting requirements.
Scalability Easy to standardise across compatible vehicle platforms. Scalable once the design has been validated for production.
Spares and serviceability Common components can simplify maintenance and replacement. May require application-specific spare parts and servicing.
Certification effort Existing product documentation can simplify assessment. Application-specific designs may require additional validation.
Best suited to Prototypes, pilot fleets, standard platforms and rapid expansion. Unusual chassis designs, demanding power requirements and specialised applications.

For many AGV manufacturers, modular battery systems provide the most straightforward route to deployment. They reduce the amount of development required and can simplify procurement when several vehicles share the same electrical architecture.

However, a standard pack is only cost-effective if it fits the vehicle and meets its operating requirements. If modifications to the chassis, mounting arrangement or electrical system are needed, the initial saving can quickly disappear.

Explore Elite Battery Systems’ standard battery packs for examples of established battery configurations.

Which AGV battery factors should engineers consider?

Battery selection should start with the vehicle’s actual operating profile, rather than simply matching the existing battery’s voltage.

Several factors influence whether a modular or custom solution is more appropriate.

1. Duty cycle and number of shifts

How frequently does the AGV operate, and how much energy does it consume during each shift?

A vehicle running occasional warehouse movements has different requirements from one transporting materials continuously across a 24/7 manufacturing facility.

Consider:

  • Operating hours and shifts per day.
  • Average and peak power demand.
  • Energy consumption during acceleration and movement.
  • Additional power required for lifting or other onboard equipment.
  • Required runtime between charging opportunities.

Higher utilisation may justify a higher-capacity system or a different charging strategy. The battery must support the complete duty cycle without compromising availability.

2. Opportunity charging, battery swapping or overnight charging

Charging strategy directly influences the required battery capacity and system design.

Opportunity charging allows an AGV to recharge during planned breaks or periods of inactivity. This can reduce the need for a large battery, provided the pack, charger and BMS are designed to support the charging profile.

Battery swapping can minimise vehicle downtime, but requires compatible spare packs, handling arrangements and additional charging infrastructure.

Overnight charging is simpler for fleets that operate within defined shifts, although battery capacity must be sufficient for the full operating period.

The charging system should be considered alongside the battery from the beginning. Explore Elite Battery Systems’ lithium battery chargers when assessing charging compatibility and integration.

3. Available space and vehicle weight distribution

AGV chassis designs are often compact, leaving limited room for battery installation.

A modular pack may fit the electrical specification but still create problems with mounting points, enclosure dimensions or cable routing.

Engineers should also consider the centre of gravity. Battery weight and positioning can affect vehicle stability, handling and lifting performance.

Where space is particularly restricted, a custom enclosure or battery configuration may provide a better solution without requiring significant vehicle redesign.

4. BMS communication and vehicle controller integration

An AGV battery needs to communicate effectively with the vehicle’s control system.

The Battery Management System monitors important operating parameters, including voltage, temperature, state of charge and battery health. This information helps the AGV controller make decisions about charging, operation and maintenance.

CAN bus is a common communication interface in industrial battery applications, but compatibility should never be assumed. Engineers need to confirm the required protocol, message structure, communication settings and fault reporting.

For example, Elite Battery Systems’ ICE and ZTR battery packs specify CANBUS connectivity, while its PIO 36V pack lists RS485 and Bluetooth. These demonstrate why the communication interface must be checked against the vehicle controller rather than selected by voltage alone.

5. Operating temperature and warehouse conditions

Cold-chain warehouses introduce additional battery considerations.

Low temperatures can affect available battery performance and charging requirements. The battery must be specified for the actual operating environment, including temperature variations between storage, charging and vehicle operation.

An appropriate enclosure, thermal management strategy and BMS configuration should all be considered during specification.

6. Fleet size and component commonality

For larger fleets, standardisation can make a significant difference to long-term operating costs.

Using common battery modules across multiple vehicle models can simplify spare parts management, maintenance and procurement. It may also reduce the number of different charging systems required.

However, if every vehicle has different electrical or mechanical requirements, a custom solution may offer better integration.

Why are LFP lithium batteries popular for AGVs?

Lithium iron phosphate (LFP) is a popular chemistry for industrial battery applications because of its combination of cycle life, thermal stability and operational characteristics.

For AGVs, one important advantage is its suitability for frequent charging. Automated vehicles using opportunity charging may undergo repeated partial charging cycles throughout the day rather than completing a full discharge before recharging.

LFP chemistry is well suited to this type of operating pattern when the battery and charging system are correctly specified.

Its thermal stability and established safety characteristics also make it an attractive option for unattended industrial equipment. However, chemistry alone does not guarantee safety. Cell quality, pack construction, BMS protection and system integration remain essential.

For fleets replacing lead-acid technology, a lithium AGV battery can also offer opportunities to reduce routine maintenance and improve energy utilisation.

When should you choose a custom AGV battery pack?

Customisation becomes worthwhile when standard battery modules cannot meet the vehicle’s physical or electrical requirements.

Typical examples include:

  • Unusual chassis dimensions: Where a standard enclosure cannot fit the available battery compartment.
  • High peak power requirements: Particularly where lifting mechanisms or demanding acceleration place additional loads on the battery.
  • Special operating environments: Including applications requiring specific enclosure designs or hazardous-area considerations. ATEX compliance must be assessed and validated for the complete application.
  • High-volume manufacturing: Where optimising the battery’s dimensions, weight or component selection can deliver long-term savings across production.

A custom design also gives engineers greater control over connectors, mounting arrangements, BMS functionality and communication interfaces.

Elite Battery Systems approaches customisation collaboratively, working with OEMs to understand their technical requirements before developing specifications and prototypes. This helps manufacturers achieve application-specific performance without automatically taking on the cost of a completely new battery architecture. Elite Battery Systems+1

Explore the Elite Battery Systems customisation process for more information.

When is a modular AGV battery the better choice?

Modular systems are often the more practical option when speed, cost and repeatability are priorities.

They are particularly suitable for:

  • Prototypes and pilot fleets: Using established battery technology can help reduce development time.
  • Mixed AGV fleets: Common battery configurations can simplify maintenance and spare parts.
  • Lead-acid replacements: Standard lithium configurations can provide a starting point for upgrading existing vehicles, subject to electrical and mechanical compatibility.
  • Rapid fleet expansion: Proven designs make it easier to scale production without developing an entirely new battery pack.

Modular does not have to mean inflexible. A proven battery architecture can still be adapted to meet specific application requirements.

What AGV battery voltage do most vehicles use?

There is no universal AGV battery voltage. The correct specification depends on the vehicle’s motor, controller, power requirements and existing electrical architecture.

Common industrial lithium battery configurations include 36V and 51.2V systems, although higher or lower voltages may be appropriate depending on the application.

Elite Battery Systems offers several examples of these configurations:

These are examples of available battery architectures, not automatic recommendations for AGV applications. Each would need to be assessed against the vehicle’s electrical, mechanical and operational requirements. Elite Battery Systems+2

How does Elite Battery Systems approach AGV battery customisation?

The best solution is not always completely standard or completely bespoke.

Elite Battery Systems takes a hybrid approach, using proven modular battery technology as a starting point and adapting the system where the application demands it.

This can include:

  • Custom enclosure dimensions and mounting arrangements.
  • Battery voltage and capacity configurations.
  • BMS selection and integration.
  • Communication interfaces to suit vehicle controllers.
  • Charging system compatibility.

This approach provides the flexibility of application-specific engineering without the unnecessary expense of developing every component from scratch.

With fast prototyping and scalable manufacturing capabilities, Elite Battery Systems supports OEMs from initial specification through to production. Whether developing a new AGV platform or upgrading an existing fleet, the objective is to deliver a reliable, cost-effective battery system that meets the vehicle’s requirements. Elite Battery Systems+1

AGV battery specification checklist: what should you confirm?

Before selecting a battery system, make sure the following information is available:

  • Required nominal voltage and operating voltage range.
  • Capacity and usable energy requirements.
  • Continuous and peak power demand.
  • Daily operating hours and duty cycle.
  • Charging method and available charging windows.
  • Maximum battery dimensions and weight.
  • Mounting points and connector requirements.
  • BMS communication protocol and controller compatibility.
  • Operating and charging temperature ranges.
  • Required safety, transport and application-specific compliance.

Having these details available makes it easier to establish whether a standard modular pack is suitable or whether customisation is necessary.

Frequently asked questions about AGV batteries

Can I retrofit a lithium battery into an existing lead-acid AGV?

Yes, many AGVs can be upgraded from lead-acid to lithium batteries. However, the replacement must be compatible with the vehicle’s voltage, available battery space, weight distribution, connectors and control system. The charger will also need to be compatible with the new battery chemistry and BMS.

Is a modular AGV battery cheaper than a custom battery pack?

Generally, modular battery systems have lower upfront development costs because they use established designs and components. Custom packs may require additional engineering and prototyping, but can deliver better long-term value where space, performance or production volumes justify the investment.

Do AGV batteries need a battery management system?

Yes. A BMS is an important part of a lithium AGV battery system. It monitors battery conditions, manages charging and discharging, and provides protection against operating conditions that could damage the battery. Communication with the AGV controller also allows the vehicle to monitor battery status and manage charging requirements.

Find the right AGV battery solution with Elite Battery Systems

Selecting an AGV battery is about more than choosing between standard and custom designs. It requires an understanding of vehicle architecture, duty cycles, charging requirements and integration constraints.

For many manufacturers, the best approach is modular where possible and custom where necessary.

Elite Battery Systems works with AGV and AMR manufacturers to develop cost-effective lithium battery solutions, combining proven battery technology with application-specific customisation.

Looking for the right battery for your AGV fleet? Explore our AGV battery solutions or contact the team to discuss your vehicle specifications and request technical data sheets.