AGV Battery Types: Lead-Acid vs AGM vs Lithium vs LiFePO4

Choosing the right AGV battery is one of the most important decisions you make for an automated guided vehicle project. The battery chemistry you pick will decide how long your AGVs can run, how often they must stop for charging, how reliable your system is – and how much you really pay over the lifetime of the fleet.

In this guide we’ll walk through the most common AGV battery types – lead-acid, AGM, lithium-ion and LiFePO4 – and explain, in simple language, when each one makes sense and when you should move on to something better.

Which AGV Battery Type Is Best Today?

If you just want the short answer:

• Lead-acid and AGM batteries are still used in some AGV projects where budgets are very tight and utilization is low.
• For modern, multi-shift AGV fleets, most new projects are moving to LiFePO4 (lithium iron phosphate) because it offers the best combination of safety, cycle life, opportunity charging and total cost of ownership.

The table below gives a detailed comparison of the main AGV battery types.

Detailed Comparison of AGV Battery Types

Values are typical ranges, not strict limits. Actual performance depends on design, quality and operating conditions.

Aspect	Flooded Lead-Acid	AGM / GEL Lead-Acid	Standard Lithium-ion (NMC/NCA etc.)	LiFePO4 (LFP) Lithium
Typical use in AGVs	Older or low-duty AGVs, manual conversion projects	Slightly newer AGVs, where maintenance-free lead-acid is preferred	Some high-performance AGVs, often with stricter thermal control	Most new AGV and AMR platforms
Typical cycle life (to ~80% capacity)	~800–1,200 cycles	~1,000–1,500 cycles	~2,000–3,000 cycles	3,000–6,000+ cycles
Recommended depth of discharge (DoD)	50–60%	60–70%	80–90%	80–90%
Charging time	Long; often 8+ hours for full charge	Still several hours, faster than flooded but not “fast charging”	Significantly faster; suitable for fast charging	Very suitable for fast and opportunity charging
Maintenance	High – watering, cleaning, equalization charge	Low – maintenance-free but still needs care	Maintenance-free	Maintenance-free
Weight and size	Heaviest and bulkiest	Slightly lighter than flooded	Much lighter and more compact	Light, compact, good energy density for AGV
Upfront cost	Lowest purchase price	Slightly higher than flooded	Higher	Higher than lead-acid, similar or lower than other lithium in many cases
Cost per kWh over lifetime	Often high, due to short life and downtime	Still relatively high	Lower	Usually lowest overall TCO for AGVs
Opportunity charging suitability	Poor – frequent partial charging shortens life	Better than flooded, still not ideal	Good	Excellent – designed for partial and frequent charging
Safety	Acid, gas emission, corrosion, spill risk	Sealed, less spill risk	Needs strong BMS and thermal management	Very good intrinsic safety, stable chemistry
Best for…	Low-duty, single-shift, lowest upfront budget	Retrofitted AGVs where only small improvement is needed	High-performance AGVs with tight space and cooling	Multi-shift AGVs, warehouses and factories focused on uptime

You can already see the pattern: lead-acid wins on purchase price, but LiFePO4 wins almost everywhere else – especially for AGVs that must run many hours per day.

What Is an AGV Battery (and Is It the Same as an AGM Battery)?

Before comparing types, we must clear up a very common confusion:

• AGV stands for Automated Guided Vehicle – it is the machine, the vehicle.
• AGM stands for Absorbent Glass Mat – it is a design of lead-acid battery, not a vehicle.

So:

An AGV battery is any traction battery used to power an automated guided vehicle.
An AGM battery is just one possible type of lead-acid battery that can be used in an AGV.

What is an AGV battery?

An AGV battery is more than just a box of cells:

• It provides traction power for the drive motors and on-board electronics.
• It normally includes a Battery Management System (BMS) or at least protections.
• It may communicate with the vehicle controller over CAN or RS485 to share state-of-charge and alarms.
• It sits in a robust industrial enclosure designed for frequent charge/discharge cycles, vibration, and sometimes automatic battery changing systems.

Because AGVs are often unattended and run on tight schedules, their batteries must be:

• Highly reliable
• Able to work with fast and opportunity charging
• Safe under repeated shallow and deep cycles

What is an AGM battery?

An AGM battery is a type of sealed lead-acid battery where:

• The acid electrolyte is absorbed in a glass-fiber mat between the plates.
• The battery is sealed with a pressure valve, so under normal use it doesn’t need watering.
• It can deliver higher currents than many flooded lead-acid batteries and is more resistant to vibration.

AGM batteries are widely used in cars, UPS systems, boats and RVs. They are also sometimes used as AGV batteries, especially in older platforms or cost-sensitive retrofits.

However, as we will see, AGM is still a lead-acid technology – it improves convenience and vibration resistance, but it does not change the basic limits of lead-acid compared with lithium or LiFePO4.

Overview of AGV Battery Types Used Today

Most AGV systems on the market today use one of these four battery types:

1. Flooded lead-acid batteries – the traditional, low-cost choice.
2. AGM / GEL lead-acid batteries – sealed alternatives that remove daily watering.
3. Standard lithium-ion batteries – higher energy density and faster charging.
4. LiFePO4 (LFP) lithium batteries – a special lithium chemistry optimized for safety and long life.

Let’s look at each one in more detail.

Lead-Acid AGV Batteries: When Do They Still Make Sense?

How lead-acid batteries work in AGV applications

Flooded lead-acid is the oldest and most familiar technology. Inside the battery:

• Lead plates sit in a liquid sulfuric acid electrolyte.
• During charge and discharge, chemical reactions cause lead and lead dioxide to change state, storing or releasing energy.
• The user must regularly check water levels and sometimes perform equalization charges.

In AGVs, lead-acid batteries are typically sized larger than their usable capacity, because:

• To achieve reasonable life, you normally use only about 50–60% of rated capacity.
• Deep cycling damages lead-acid plates and shortens life.

Advantages for AGV fleets

Lead-acid still has a few attractive points:

• Lowest upfront price – per kWh at purchase.
• Very mature and well-understood technology.
• Widely available from many local suppliers, which feels safe for some buyers.

For AGV projects that are rarely used, or for simple, single-shift operations, flooded lead-acid can still be acceptable.

Limitations and hidden costs

However, the drawbacks are serious:

• Heavy and bulky – poor energy density means large, heavy packs.
• Long charging times – many hours to recharge fully, so AGVs spend more time parked.
• High maintenance – frequent watering, cleaning of corrosion, equalization charges.
• Shorter cycle life – especially if the battery is deep-cycled or opportunity-charged.
• Safety and housekeeping issues – acid spills, gas emission, corrosion around the battery area.

The result is that the real cost per kWh delivered – including downtime and maintenance – is often higher than buyers expect.

When is lead-acid acceptable for AGVs?

Lead-acid may still be reasonable when:

• The AGV is used only a few hours per day.
• Labor for maintenance is cheap and readily available.
• The project is extremely cost-sensitive up front.
• Existing infrastructure (chargers, battery rooms) is already built for lead-acid.

For most new AGV investments aimed at high utilization and low lifetime cost, companies now look beyond flooded lead-acid.

AGM and GEL Batteries: Are They a Real Upgrade for AGVs?

What is an AGM battery in simple terms?

As mentioned, AGM (Absorbent Glass Mat) is a sealed lead-acid design:

• The acid is held in a glass-fiber separator.
• The battery is sealed and recombines most gases internally.
• There is no need for watering, and spill risk is greatly reduced.

GEL batteries use a gelled electrolyte instead of liquid, but share many similar properties and are often grouped together with AGM when discussing AGV batteries.

Pros of AGM / GEL in AGVs

Compared with flooded lead-acid, AGM / GEL offers:

• Maintenance-free operation – no watering, less corrosion and acid fumes.
• Better vibration resistance – useful in moving vehicles.
• Generally lower internal resistance, so they can support higher discharge currents.
• Slightly better performance at partial state of charge than traditional flooded batteries.

For AGV users who are tired of dealing with water and acid, AGM feels like a big improvement.

Where AGM still falls short for modern AGV systems

However, AGM is still limited by lead-acid chemistry:

• Cycle life is still typically 1,000–1,500 cycles, especially at moderate to deep cycling.
• They still do not like constant opportunity charging throughout the day.
• They are still heavy and bulky compared with lithium solutions.
• Charging is not truly fast; several hours are still required to reach full charge.

So AGM improves convenience and handling, but it does not unlock the full potential of high-automation, multi-shift AGV fleets.

When would you choose AGM for an AGV project?

AGM might be chosen when:

• You are upgrading from flooded lead-acid and want fewer maintenance issues, but cannot yet move to lithium.
• The AGV duty cycle is moderate and does not justify the cost of lithium today.
• Your existing charging infrastructure is already tuned for lead-acid.

In many cases, AGM is treated as a transition step – projects move from flooded → AGM → LiFePO4 as automation and utilization increase.

Lithium-Ion AGV Batteries: Moving Beyond Lead-Acid

Key benefits of lithium-ion for AGVs

Lithium-ion batteries, in general, offer several big advantages over any lead-acid battery:

• Higher usable capacity – you can safely use a larger percentage of the rated capacity (80–90% DoD).
• Much faster charging – allowing for fast and opportunity charging during short stops.
• Lighter weight and smaller volume – improving vehicle efficiency and design flexibility.
• Maintenance-free – no watering, no acid fumes, far less corrosion and housekeeping.
• Better cycle life – typically several thousand cycles.

These benefits align extremely well with AGV needs: long runtime, short stops, multi-shift operation and reduced maintenance.

Common lithium chemistries: NMC, NCA, LFP and others

“Lithium-ion” is a family of chemistries. Common ones include:

• NMC (Nickel Manganese Cobalt)
• NCA (Nickel Cobalt Aluminum)
• LFP / LiFePO4 (Lithium Iron Phosphate)
• and a few others in special applications.

NMC and NCA are often used in electric cars, where very high energy density is critical. For AGVs, space is important but extreme energy density is not always the main driver – safety, cycle life and cost per kWh can matter more.

Safety and protection considerations

All lithium-ion batteries require:

• A properly designed BMS to monitor voltage, current, temperature and SOC.
• Adequate thermal management to prevent overheating.
• Protection against over-charge, over-discharge and short-circuits.

Without a good BMS and integration, even the best chemistry can be unsafe. That is why serious AGV projects usually work with a specialized AGV battery manufacturer instead of generic packs.

Why many AGV users prefer LiFePO4 over other lithium chemistries

For the specific duty cycles and safety expectations of AGVs, LiFePO4 (LFP) stands out:

• Very stable chemistry with good thermal stability.
• Long cycle life, often 3,000–6,000+ cycles.
• Excellent performance at partial state of charge, ideal for opportunity charging.
• Easier to meet industrial safety standards.

This is why LiFePO4 has become the default choice for many modern AGV and AMR platforms.

Why LiFePO4 Is Becoming the Default Choice for New AGVs

LiFePO4 basics and why it suits AGV duty cycles

LiFePO4 is a lithium-ion chemistry where:

• The cathode material is lithium iron phosphate.
• It has slightly lower energy density than some NMC/NCA chemistries,
• but much better thermal stability and cycle life.

For AGVs, this translates into:

• Ability to tolerate frequent partial charges without severe degradation.
• Good performance over a wide temperature range.
• A very attractive cost per delivered kWh over the battery’s lifetime.

Performance vs lead-acid and AGM in real fleets

Compared with lead-acid and AGM in AGV applications, LiFePO4 typically offers:

• 2–4× the cycle life at similar usable capacity.
• Shorter charging windows, enabling AGVs to charge during brief stops.
• Lower weight, so the vehicle consumes less energy per mission.
• No daily maintenance, which frees up labor and reduces errors.

For AGV managers, this means:

• Higher uptime
• More predictable performance
• Lower maintenance budget
• Better support for 24/7 operation

Total cost of ownership: is LiFePO4 really cheaper over time?

Upfront, LiFePO4 packs cost more than lead-acid or AGM. But when you look at the whole life:

• You often need fewer battery replacements.
• You may need fewer spare packs because downtime is shorter.
• You save on maintenance labor and equipment.
• You save on electricity thanks to better efficiency.

For most multi-shift, high-utilization AGV fleets, LiFePO4 delivers a lower cost per kWh delivered and a faster payback, even if the initial quote is higher.

Typical LiFePO4 AGV battery configurations

Most LiFePO4 AGV batteries are built around common voltages such as:

• 24 V systems for smaller AGVs and light-duty robots.
• 48 V systems for medium-sized AGVs.
• Higher voltages for large or very powerful vehicles.

To see an example of how LiFePO4 AGV batteries are configured into real products (24 V, 48 V and custom packs), you can refer to the AGV Battery 24V/48V LiFePO4 packs on SAFTEC’s product page.

How to Choose the Right AGV Battery Type for Your Project

Choosing a battery chemistry is not only about technology; it is about matching your business and technical requirements.

Key questions to ask before choosing a chemistry

Ask yourself:

1. How many hours per day will each AGV run?
2. How many shifts do you have – one, two or three?
3. When and how long can the AGV stop to charge?
4. How long do you expect the battery to last (in years and cycles)?
5. What is your real budget – only initial cost, or total cost of ownership?
6. What temperatures will the AGVs see in operation and charging?
7. Do you have staff available to maintain lead-acid batteries safely?

Scenario examples

• Low-duty, single-shift AGVs with very tight budgets
  • Lead-acid or AGM may still be acceptable.
• Medium-duty, one-to-two-shift AGVs with limited opportunity charging
  • AGM or entry-level lithium solutions could work.
• High-duty, multi-shift AGVs with automatic chargers and high automation
  • LiFePO4 is usually the best choice in terms of uptime and total cost.

Technical checks with your AGV or battery partner

Whatever chemistry you choose, you must verify:

• System voltage and maximum current requirements.
• Battery compartment dimensions and weight limits.
• BMS communication protocol (CAN, RS485, etc.).
• Required safety certifications and standards in your country or industry.

A specialized AGV battery manufacturer can help you balance these factors and propose an appropriate chemistry and pack design.

Upgrading Existing AGVs: When to Move from Lead-Acid or AGM to LiFePO4?

Many companies already have AGVs running on lead-acid or AGM batteries and are wondering whether it is time to upgrade.

Signs your current AGV batteries are limiting performance

Typical warning signs include:

• AGVs cannot finish a shift without swapping batteries.
• Operators spend a lot of time dealing with battery maintenance and charging.
• You must maintain a large pool of spare batteries just to keep vehicles running.
• Battery-related downtime is causing production or logistics delays.

Drop-in vs full system redesign

An upgrade can take two approaches:

• Drop-in replacement
  • New LiFePO4 pack with the same voltage, similar size and connectors, possibly with built-in BMS and protection.
  • Often requires checking the charger and may require a new charger profile.
• Full system redesign
  • You redesign the battery compartment, charger and sometimes the DC bus.
  • Best choice when planning a new generation of AGVs rather than only updating old ones.

Safety and integration checks before upgrading

Before switching chemistries, make sure to check:

• Mechanical compatibility – mounting points, cable routing, cooling.
• Electrical compatibility – voltage limits, inrush currents, contactor ratings.
• Charging – charger type, protocols and charging profiles.
• Thermal behavior – especially at low or high ambient temperatures.
• Compliance with relevant standards and regulations.

Working with an experienced AGV battery supplier simplifies these checks and reduces project risk.

Checklist for Comparing AGV Battery Proposals

When you receive quotes from different vendors, don’t just compare price and capacity. Use this checklist:

• Battery type and chemistry (flooded lead-acid, AGM, lithium-ion, LiFePO4)
• Usable capacity (taking into account recommended DoD)
• Rated cycle life at specified DoD and temperature
• Charging time and maximum charge current
• Opportunity charging capability (yes / limited / no)
• Operating temperature range and options for heating or cooling
• BMS features – protections, logging, CAN/RS485 communication, SOC accuracy
• Physical dimensions and weight – fit with your AGV design
• Safety components – fuses, contactors, isolation monitoring, etc.
• Certifications – relevant safety and performance standards
• Warranty terms – years and cycle coverage
• Service and support – local support, remote diagnostics, spare parts
• Total cost of ownership – estimated cost per delivered kWh over the expected life

A cheaper battery that fails early or causes downtime is often more expensive than a well-engineered LiFePO4 solution.

When to Talk to an AGV Battery Manufacturer Like SAFTEC

If you are still unsure which AGV battery type to choose, or if you are planning to upgrade from lead-acid or AGM to LiFePO4, that is usually the moment to talk directly to a specialized AGV battery manufacturer.

A good partner can:

• Analyse your duty cycle, charging windows and environment.
• Recommend the right chemistry and pack size.
• Design packs that match your mechanical and electrical interface.
• Provide OEM / ODM solutions, including cell-ready packs if you want to choose your own cell supplier.

LiFePO4 is quickly becoming the standard choice for new AGV projects, but every fleet is unique. The right manufacturer will help you turn these general principles into a concrete, reliable battery system that keeps your AGVs working shift after shift.